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SpaceX scraps Florida Starship Mk2 prototype

SpaceX has begun scrapping one of the original Starship prototypes and the only ship built in Florida. (John Winkopp - Seamore Holdings)

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SpaceX has scrapped the lone Starship prototype built in Florida in 2019, surprising very few.

Beginning a few months after work began on Starship Mk1 at SpaceX’s South Texas production facilities, a separate team in Cocoa, Florida was tasked with building a similar Starship Mk2 prototype. Not much is known about Mk2 relative to its much more publicized sibling but unofficial photos and videos taken over the course of 2019 suggested that SpaceX had effectively completed most of Starship Mk2 by the end of last year. However, built dozens of miles and several waterways away from a practical test facility, actually testing a Starship prototype assembled at SpaceX’s Cocoa facilities was always going to be an uphill battle.

To warrant the cost and effort that would be required to transport something as large as a vertical Starship from Cocoa, Florida to Cape Canaveral, Mk2 would have to be able offer something invaluable during testing. Now eight months after Starship Mk1 was destroyed during one of its first real tests, that was sadly not the case and SpaceX has chosen the simplest route forward – scrapping Mk2 where it sits.

Starship Mk2 is pictured in September 2019. (Greg Scott)

In November 2019, SpaceX installed Starship Mk1 on a test stand in Boca Chica, Texas and began a series of tests. The ship passed an initial ambient temperature pressure test on the 18th but failed spectacularly during its first cryogenic proof test, said by SpaceX to have “pressurize[d] systems to the max.” Excluding Starhopper, Starship Mk1 was about as rough of a prototype as SpaceX could have feasibly built and the fact that it survived any length of time under cryogenic loads and pressures was fairly impressive.

Welded together almost entirely out in elements on the South Texas Gulf coast, the total success of Starship Mk1 (and its similar Mk2 sibling) would have flown in the face of almost every single tenet of modern aerospace production. As noted in a Teslarati article describing the Starship’s demise, the Mk1 production apparatus left plenty of room for improvement.

“[Videos of the failure implicated] the weld connecting the LOX dome to the cylindrical body of Starship’s LOX tank, pointing to a bad weld joint as the likeliest source of the failure. Although that hardware failure is unfortunate, Mk1’s loss will hopefully guide improvements in Starship’s design and manufacturing procedures.”

Teslarati.com — November 20th, 2019

That is precisely what SpaceX did – and was likely already doing – in response to Mk1’s failure. Just two months later, SpaceX successfully tested a steel Starship tank built in upgraded facilities with upgraded methods and reached pressures of 7.1 bar (~103 psi) before failing – likely a 50% improvement or better relative to Mk1. A second tank completed weeks later in late January 2020 reached 7.5 bar, sprung a leak, was repaired, and ultimately soared to 8.5 bar (~125 psi) before failing. Per CEO Elon Musk, that would technically be enough for a Starship to launch humans into orbit with an industry-standard ~40% safety factor.

Finally, SpaceX recently proved that a full-scale, two-tank Starship prototype built with the same methods and facilities as those test tanks could achieve the same results, completing a ~7.5 bar (~110 psi) cryogenic proof test with Starship SN4 on May 10th.

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Long story short, the methods SpaceX used to build Starship Mk1 and Mk2 were already proven redundant more than six months ago and buried even deeper in May 2020. Aside from serving as a museum piece, Starship Mk2’s fate was sealed – the only real question was how and when it would be scrapped. For now, SpaceX’s Starship program will be almost exclusively stationed in South Texas, where it appears to be in good hands. Starship SN5 is currently expected to attempt its first wet dress rehearsal (WDR) and static fire tests no earlier than July 17th (today) at 8 am CDT (13:00 UTC).

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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