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Elon Musk: SpaceX’s first orbital Starship launch “highly likely” in Q1 2023

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SpaceX’s first Starship orbital launch mount (OLM) appears to have passed a busy week of stress-testing, clearing the way for the company to transport a finished Super Heavy booster to the pad.

Using the same launch mount, that Starship booster is expected to attempt to complete some of the riskiest and most challenging tests SpaceX has ever conducted at its Starbase rocket development facilities. The schedule for that testing is unclear, but after an unusually drawn-out period of qualification testing, Super Heavy Booster 7 (B7) could soon attempt a full static fire test of all 33 of its Raptor 2 engines. Either before or after that crucial test, SpaceX is also expected to install Ship 24 (S24) on top of Super Heavy B7 for Starship’s first full-stack “wet dress rehearsal.”

Ultimately, if that testing produces the results SpaceX wants to see, CEO Elon Musk says that Starship could attempt its first orbital launch as early as late February or March 2023.

Booster 7

Super Heavy B7 first left SpaceX’s Starbase factory in March 2022 and has been in a continuous flux of testing, repairs, upgrades, and more testing in the nine months since. The 69-meter-tall (~225 ft), 9-meter-wide (~30 ft) steel rocket was severely damaged at least twice in April and July, requiring weeks of substantial repairs. But neither instance permanently crippled the Starship booster, and Booster 7 testing has been cautious but largely successful since the rocket’s last close call.

Following its return to the OLS in early August, Super Heavy B7 has completed six static fire tests of anywhere from one to fourteen of its 33 Raptor engines. It has almost certainly dethroned Falcon Heavy to become the most powerful SpaceX rocket ever tested. And on January 8th, 2023, SpaceX rolled the rocket back to Starbase’s orbital launch site (OLS) for the seventh time. According to statements made by CEO Elon Musk and a presentation from a NASA official, the last major standalone test between Booster 7 and flight readiness is a full 33-engine static fire. Together, B7’s 33 Raptor 2 engines could produce up to 7600 tons (16.7 million lbf) of thrust at sea level, likely making Starship the most powerful rocket stage in the history of spaceflight.

Booster 7 last completed a long-duration 11-Raptor static fire. (SpaceX)

Ship 24

Starship prototype S24’s path has been a bit less rocky. The ship has needed some less obvious repairs, particularly right after its first tests in May 2022. Since August 2022, Ship 24 has completed three static fire tests – all seemingly successful. Most importantly, one of those tests ignited all six of S24’s Raptor engines, potentially qualifying it for an orbital launch attempt. Most recently, SpaceX completed a series of mysterious repairs, replaced and static-fired one of S24’s engines, and removed the Starship from its test stand.

With Booster 7 now awaiting installation on Starbase’s orbital launch mount and Ship 24 near-simultaneously removed from its test stand, it appears that SpaceX may attempt a different test before Super Heavy’s full static fire. Instead, SpaceX could start by stacking Ship 24 and Booster 7 and conducting a full-stack wet dress rehearsal (WDR) before shifting focus to Booster 7’s riskier static fire.

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A wet dress rehearsal is a routine test conducted before a rocket launch and is generally designed to simulate every aspect of a launch save for engine ignition and liftoff. Most importantly, that involves fully filling the rocket with propellant and passing all of the checks the same rocket would need to pass to be cleared for launch. For Starship, the largest rocket ever built, a full propellant load means filling both stages with an extraordinary ~5000 tons of liquid oxygen and liquid methane propellant. SpaceX also needs to fill the rocket fast enough to keep that propellant supercool, which increases its density and overall performance.

The first full-stack WDR will thus test Starbase’s launch facilities just as much as Booster 7 and Ship 24. SpaceX has conducted many several Starship WDRs, but not with Ship 24. It’s also never fully filled a Super Heavy booster with real propellant, let alone both stages at once. It’s likely that issues will be discovered as SpaceX pushes the envelope, likely requiring multiple attempts.

OLS

In the spirit of caution, SpaceX has even taken the unusual step of stress-testing Starship’s orbital launch mount with a custom jig. In the first week of 2023, SpaceX used that jig to load pairs of the OLM’s 20 hold-down clamps with hundreds of tons of ballast, ensuring that they can withstand the immense weight of a fully-fueled Starship. Proof tests of Super Heavy B4 and B7 have likely subjected the OLM to 2000+ tons of force, but a full Starship will weigh more than double the maximum weight the OLM has experienced to date.

Plenty of risk remains and SpaceX is trading speed for caution, but this extra-cautious step has likely reduced the risk of the launch mount’s structure failing during wet-dress and static fire testing. According to Musk, SpaceX has a “real shot” at preparing Starship for a “late February” orbital launch attempt. Nonetheless, Musk also implied that a full-stack WDR and 33-engine static fire would “probably” be completed “in a few weeks” in September 2022. What is clear is that SpaceX is more committed than ever before to avoiding a catastrophic failure during Starship’s first orbital launch attempt.

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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SpaceX readies Starship Flight 14 for a historic journey into uncharted territory

SpaceX finished Starship’s Flight 14 rehearsal, clearing the way for its first orbital flight Monday.

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Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX
Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX

SpaceX has cleared one of the last hurdles before Starship’s first trip to orbit. The company posted on X Thursday afternoon that its launch rehearsal for Flight 14 was complete, keeping the mission on track for Monday, September 28. The launch window opens at 7:15 a.m. CT at Starbase, Texas, and runs for 75 minutes.

A wet dress rehearsal is essentially launch day without the launch. Crews fill Booster 21 and Ship 41 with thousands of tons of extremely cold propellant, run the countdown nearly to ignition, then drain everything back out. It lets engineers catch leaks or equipment problems before anything leaves the pad. SpaceX still needs a launch license from the FAA before the stack, which stands 407 feet tall, can fly.

Flight 14 matters because of where it is going. All 13 previous Starship flights followed a suborbital path, which works like throwing a ball extremely high and far: the vehicle reaches space, but it is always on a course that brings it back down within about an hour. This time, Ship 41 will perform a short engine firing called an orbital insertion burn roughly 25 minutes after liftoff, giving it enough speed to keep falling around Earth instead of back into it. SpaceX plans about six laps at an altitude near 275 kilometers (171 miles) over nearly 10 hours, as Teslarati detailed when the mission was first announced.


Getting into orbit also means Starship has to prove it can get back out. The ship must relight a single Raptor engine in space to slow down for reentry. SpaceX says it will only attempt the orbital insertion burn after flight controllers confirm the hardware needed for that return burn has enough backup, and its flight plan includes health checks that could shorten the mission to two or five orbits.

Flight 14 is also the first to put working satellites into service. Flight 13 carried 20 Starlink V3 satellites in July, but they came back down with the ship because that mission never reached orbit. This time, 26 V3 satellites are meant to stay up and join the constellation within a few weeks. Together they add about 26 terabits per second of network capacity, which SpaceX says is roughly 10 times what a single Falcon 9 launch of older V2 Mini satellites adds. Three of them carry cameras that will photograph Starship’s heat shield in orbit to check for tile damage before reentry.

The hardware has changed too. Ship 41 flies with extra fasteners on tiles in the most vulnerable areas, fixes for gaps where superheated plasma slipped behind tiles, and curved tiles designed to reduce heating between them. Two tiles recovered from Ship 40 will fly again, the first reuse of any part of a Starship heat shield. Booster 21 carries better engine filtering and new relight software after ice clogged three center engines on the previous booster, leaving only eight of 13 engines to restart for its landing burn.

Ship 41 is targeting a splashdown in the Pacific Ocean west of Chile, a new recovery zone after several Indian Ocean landings, while Booster 21 aims for the Gulf. Neither will be caught by the tower on this flight. Elon Musk said in August that a ship catch was likely “in a few months.”

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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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