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SpaceX Starship pop test opens the door for 60,000 foot hop [update]

SpaceX has successfully destroyed a Starship 'test tank' for the fourth time. (NASASpaceflight - bocachicagal)

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SpaceX has successfully destroyed a Starship ‘test tank’ for the fourth time, opening the door for the first high-altitude prototype to roll to the launch pad as soon as tomorrow.

The culmination of three nights and more than 20 hours of concerted effort, SpaceX was finally able to fill Starship test tank SN7.1 with several hundred tons of liquid nitrogen before dawn on September 23rd. With just an hour left in the day’s test window, SpaceX closed the tank’s vents, allowing its cryogenic contents to boil into gas and expand with no outlet. At 4:57 am CDT, SN7.1 burst, bringing its lengthy test campaign to a decisive end.

A handful of hours later, new road closure notices revealed SpaceX’s plan to roll Starship SN8 – the first full-size prototype and first ship meant for high-altitude testing – from its Boca Chica factory to the launch site.

Update: All road closures planned for Starship SN8’s roll to the launch pad (Sept 24) and first test campaign (Sept 27-29) have been canceled. Stay tuned for updates on the high-altitude prototype’s test schedule.

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Short of new information from SpaceX or CEO Elon Musk, little is known about the results of SN7.1’s lengthy test campaign, but the fact that it survived two nights of nondestructive testing – including the use of hydraulic rams to simulate Raptor thrust – effectively clears Starship SN8 for suborbital testing. Based on a speculative, amateur analysis of the aftermath of SN7.1’s burst test, it can also be tentatively concluded that the tank failed almost exactly where one would expect it to: the in-situ weld attaching the upper tank dome to SN7.1’s steel ring hull.

SN7.1’s forward dome appears to have cleanly sheared off around much of its circumferential weld joint – exactly what one would theoretically expect from a good, uniform weld. Assuming that SN7.1 reached pressures well above 8.5 bar (~125 psi) before it burst, the tank’s final test can likely be deemed a success.

The very same day SpaceX kicked off what would become Starship SN7.1’s last burst test attempt, teams worked to install functional flaps on a full-scale Starship prototype (SN8) for the first time ever. Effectively answering the question of whether SpaceX would fully outfit the ship with a nosecone and flaps before its first acceptance tests, SN7.1’s successful pop was followed by road closure notices for SN8’s transport to the launch pad around dawn on September 24th and cryptic “SN8 Testing” as early as September 27th.

As of September 23rd, SN8’s twin aft flaps – large aerodynamic control surfaces meant to stabilize free-falling Starships – have been fully installed alongside ‘aerocovers’ that will protect each flap’s control mechanisms. The only hardware Starship SN8 is missing is a ~20m (~60 ft) tall nosecone, two smaller forward flaps, and the plumbing needed to access a smaller liquid oxygen “header” tank located in the tip of said nose.

At the moment, SpaceX has installed one Starship nosecone prototype atop five unpressurized rings – creating a full nosecone stack. That particular prototype has no liquid oxygen header tank, however, meaning that SpaceX would likely need at least a day or two to weld one of the noses with a header tank atop one of several finished five-ring sections. In other words, to transport SN8 to the pad tomorrow, there’s almost no chance that SpaceX will have time to finish and install a proper nosecone on the prototype, meaning that the company has chosen to test the Starship before that milestone.

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Starship SN8’s tank section is effectively complete as of September 23rd. (NASASpaceflight – bocachicagal)

Doing so should reduce any inconvenience caused by vehicle failure in the event that Starship SN8’s acceptance test campaign doesn’t go as planned. In hindsight, the inclusion of Starship SN8’s aft flaps and aerocovers during the ship’s first major tests was likely a necessity, given that almost half of each flap and its support structure is installed directly to the skin of its liquid oxygen tank. Theoretically, when chilled to the temperature of liquid nitrogen or oxygen, the diameter of the stainless steel rings Starship SN8 is built out of could shrink by as much as 0.3% (~20 mm or ~0.8 in).

Only half of Starship SN8’s aft flaps will be directly subject to that tank contraction, resulting in a relatively complex environment for such a large, high-stress mechanical system. As such, testing flap actuation under cryogenic loads is likely a critical part of SN8’s cryogenic proof test, otherwise meant to demonstrate the structural integrity and functionality of Starship’s propellant tanks. If SN8 rolls to SpaceX’s launch facilities on schedule, the Starship’s first cryogenic proof test could begin as early as 9pm CDT (UTC-5) on Sunday, September 27th.

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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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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