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SpaceX close to securing FAA license for Starship launch debut

A SpaceX director believes that Starship's orbital launch license will be granted imminently after a busy period of successful tests.. (SpaceX)

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A senior SpaceX director expects the United States Federal Aviation Administration (FAA) to grant a license for the first orbital launch of its next-generation Starship rocket in the “very near future.”

Speaking at the 2023 Space Mobility Conference, SpaceX Senior Director of National Security Space Solutions Gary Henry also indicated that Starship remains on track to launch as early as March 2023. Six weeks ago, CEO Elon Musk tweeted that SpaceX had “a real shot at [a] late February” Starship launch, adding that a “March launch attempt [appeared] highly likely.” February is now out of reach. But March may still be a viable target, according to Henry.

SpaceX has made significant progress towards Starship’s first orbital launch attempt in early 2023. On January 23rd, Ship 24 and Super Heavy Booster 7 were filled with around 4800 tons (~10.6M lbs) of propellant and completed Starship’s first full wet dress rehearsal, simulating a launch attempt up to the moment before engine ignition.

Two and a half weeks later, SpaceX attempted to ignite all 33 of Booster 7’s Raptor 2 engines. 31 engines ignited as planned, producing 3580 tons (7.9M lbf) of thrust – the most powerful static fire test in the history of rocketry. SpaceX and CEO Elon Musk have been relatively quiet about the test, merely noting that Starship may have still been able to reach orbit if it had lifted off with 31 of 33 engines.

Starship successfully completed its two most challenging, unprecedented tests – a full wet dress rehearsal and (nearly) full static fire – just a few weeks apart. (SpaceX)

By all appearances, the test was a spectacular success for SpaceX. 94% of Super Heavy’s Raptors ignited on the first attempted 33-engine test. The booster – standing as tall as an entire two-stage Falcon 9 rocket with a payload fairing – then safely drained its tanks. Booster 7 suffered no apparent damage, and SpaceX hasn’t removed or replaced any of its Raptor engines, potentially indicating that all 33 are healthy enough to stay on the booster for Starship’s first orbital launch attempt. That in itself is a major achievement.

On February 21st, SpaceX’s Gary Henry confirmed that Super Heavy Booster 7 and the launch pad that supported its record-breaking static fire test are in “good shape.” Counter to virtually all other large rockets in history, Starship’s first orbital launch pad has no water deluge system, flame trench, or thrust diverter to suppress or redirect the incredible amount of energy the rocket’s engines can produce. Despite that ommittance, the flat concrete directly below the pad appeared to survive almost eight million pounds of thrust and brutal heat with only minor spalling and damage.

The concrete adjacent to the orbital launch mount fared less well, but may eventually be replaced with the same high-temperature Fondag concrete that was added under the mount. If the launch mount and its surroundings are in “good shape” after experiencing about half of Starship’s full thrust, it’s possible that SpaceX will be ready to launch in the near future.

In the meantime, SpaceX is already installing a water deluge system that will eventually make its South Texas Starship launch site much more capable of withstanding the stress of Starship tests and launches. Installing that system and building a sufficiently massive water supply will take months, however, and would likely preclude a March launch attempt, indicating that SpaceX’s first orbital Starship launch attempt will happen without it.

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SpaceX has, however, begun installing a final layer of shielding on Starbase’s orbital launch mount. That task will likely need to be completed before the launch attempt and could take a couple weeks.

The strongest sign that Starship’s first orbital launch attempt is imminent will be Ship 24’s return to the pad and reinstallation atop Booster 7, as well as SpaceX’s receipt of an FAA launch license. With testing mostly behind SpaceX, that license to launch may now be the biggest source of uncertainty for Starship’s orbital-class debut. If, as Gary Henry and spaceflight journalist Christian Davenport have indicated, there are no major hurdles standing in the way of that FAA license, Starship could be ready to launch in a matter of weeks.

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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Cybertruck

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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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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