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SpaceX’s Starship program returns to its roots with a new rocket ‘test tank’

SpaceX appears to be re-upping a tried and true foundation of its Starship development with a new rocket 'test tank'. (NASASpaceflight - bocachicagal)

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SpaceX’s Starship rocket development program has returned to its early-2020 roots as teams work to assemble the first new ‘test tank’ built in South Texas in more than three months.

Just like its three predecessors, the newest test tank’s purpose is relatively simple: demonstrate – at full scale – the efficacy of SpaceX’s current manufacturing processes. Back when SpaceX built and tested the first two tank prototypes in January 2020, the company was in the midst of making big changes throughout its coastal Boca Chica, Texas Starship factory – a major leap forward compared to the methods used to build Starship Mk1. While the first tank made it to 7.1 bar (~103 psi) before failing, a second tank survived all the way up to 8.5 bar (~125 psi), as did a third separate test tank built about a month later. According to CEO Elon Musk, 8.5 bar is more than satisfactory for Starship pressure vessels to safely launch humans into orbit, offering a safety margin of more than 40%.

Most recently, Starship SN4 became the first full-scale prototype to replicate the results SpaceX achieved with its shorter test tanks, effortlessly reaching 7.5 bar (~110 psi) during a cryogenic pressure test completed just last month. Despite those myriad successes, however, SpaceX rarely stops moving forward and Musk has already hinted at improvements the company may be hoping to prove out with a fourth Starship test tank.

SpaceX appears to be re-upping a tried and true foundation of its Starship development with a new rocket ‘test tank’. (NASASpaceflight – bocachicagal)

The most obvious reason to build a new test tank after the success of full-scale Starship prototype SN4 is a substantial change in the steel alloy SpaceX is building rockets out of in South Texas. CEO Elon Musk has teased such a shift for almost a full year and it appears to have happened right on time – if not ahead of schedule. SpaceX currently uses 301 stainless steel for Starship production, while the new material – discussed earlier by Musk and confirmed by inscriptions on the exterior of what would later become the fourth test tank – is a slightly different 304 steel “with higher ductility” (malleability).

What was initially was initially labeled “SN7” later became the fourth Starship test tank in June 2020. (NASASpaceflight – bocachicagal)

It’s unclear if this is the custom-built “30X” alloy SpaceX was planning on creating, given that “304L” steel is an already-available commodity material that is slightly more durable and corrosion-resistant but less ductile and ~10% more expensive than 301. Regardless, changing to a new alloy would almost certainly benefit from real-world testing to confirm that behaves in the ways SpaceX expects it to, while also verifying that existing fabrication methods (particularly welding) still suffice.

Test Tank #1, January 9th, 2020. (NASASpaceflight – bocachicagal)
Test Tank #4 – also known as Starship SN7 – is pictured here on June 5th. (NASASpaceflight – bocachicagal)

The only other notable visual differences between Starship Test Tank #4 and its predecessors are small changes in welding. On the new tank’s dome and ring, SpaceX has removed wavy strips of metal known as a weld doublers, used to strengthen vertical welds on all previous ships and test tanks. While only realizing miniscule weight savings, the change is a visual confirmation that SpaceX is growing more confident in its weld quality, perhaps also signifying the introduction of a new kind of welding.

Last but not least, the circumferential weld joining Test Tank #4’s dome and ring (a dark horizontal line) appears to be centered on the ring, whereas the domes of previous ships and tanks have typically been attached to the upper or lower 20-30% of their respective rings. The purpose of this change is unknown.

Regardless, Test Tank #4 is currently in the midst of an hours-long cryogenic proof test and appears to be almost fully loaded with several hundred tons of liquid nitrogen. Check out the frosty tank live at the link below as we wait to see if the Starship hardware survives.

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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 has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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How SpaceX Is raising Raptor’s sea-level thrust while holding engine mass steady

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Credit: SpaceX

SpaceX’s Raptor engine family has steadily increased sea-level thrust while simultaneously reducing mass, turning iterative engineering gains into substantially higher performance for the Super Heavy booster. CEO Elon Musk shed more light on how powerful Raptor 4 will be, and it’s pretty crazy.

Raptor 1 delivered 185 metric tons of thrust at roughly 2,080 kilograms, while Raptor 2 raised that to 230 tons while cutting mass to about 1,630 kilograms. SpaceX data for Raptor 3 lists a target of 280 tons at 1,525 kilograms (with further reductions in associated vehicle hardware), while operational flight ratings have been cited near 250 tons.

This morning, Elon Musk stated that Raptor 4 is expected to reach 300 tons of sea-level thrust at roughly the same mass as Raptor 3. Across these versions, thrust has risen by more than 60 percent from the first engines while engine mass has fallen, producing a sharp improvement in thrust-to-weight ratio. This is a true testament to how great SpaceX engineering has been:

With 33 engines on SuperHeavy, the jump from earlier versions to a 300-ton Raptor 4 would produce roughly 9,900 metric tons of total liftoff thrust, nearly three times the Saturn V’s approximately 3,400 metric tons from its five F-1 engines.

This is not just a larger number on a data sheet, either, as sea-level thrust is the force available the moment the vehicle leaves the pad. This is when it is heaviest and still deep in Earth’s gravity well and dense atmosphere.

Higher levels of sea-level thrust directly improves the initial thrust-to-weight ratio of the full stack. A higher ratio produces faster acceleration off the pad, which shortens the time the rocket has to spend fighting gravity, and gravity losses during the first minute or two of the flight are a major drain on total available delta-v. Every second shaved off of that early climb preserves more propellant energy for reaching orbital velocity or for carrying extra payload.

Because Super Heavy’s engine count is constrained by vehicle diameter and packing density, increasing thrust per engine is the most straightforward way to raise total liftoff performance without redesigning the booster structure or design.

The same-mass target for Raptor 4 is equally important. Holding engine mass roughly constant while raising thrust improves the engine’s own thrust-to-weight ratio and reduces the structural and propellant mass fraction that must be carried solely to support the engines.

Earlier Raptor iterations also simplified or eliminated extensive vehicle-side hardware such as heat shields. These gains compound: more force for less installed mass leaves additional capacity for propellant, payload, or operational margins such as engine-out capability.

For Starship’s architecture, the practical effects are large. Greater liftoff thrust supports heavier vehicles, larger propellant loads, and higher payloads to low Earth orbit, figures SpaceX has targeted in the 100-plus-ton reusable range. That capacity underpins orbital refueling, lunar missions, and eventual Mars cargo and crew flights.

Continued growth in sea-level thrust therefore tightens the gap between theoretical rocket performance and the high flight rates and reusability needed to make large-scale space transport practical.

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Tesla Assisted Driving expands to tenth EU country

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Tesla has expanded its Tesla Assisted Driving (TAD) suite to its tenth European country, as Latvia joined a growing list of European Union member states authorizing the company’s advanced driver assistance technology.

Tesla Europe announced this morning that the system is now approved in Latvia, with a software rollout to begin soon.

The approval and rollout follow recognition of a provisional European type approval originally granted by the Netherlands’ RDW authority on April 10.

Latvia’s Road Traffic Safety Directorate (CSDD) evaluated the Dutch documentation, coordinated with the other national authorities, and reviewed updates from Tesla. These included tightened limits on speed offsets, automatic resets of any manual speed adjustments after each trip, and stronger driver monitoring.

In Europe, the feature is marketed as Tesla Assisted Driving after a recent rule change that labeled the name “Full Self-Driving” as misleading.

Tesla starts showing how FSD will change lives in Europe

The system remains an SAE Level 2 driver assistance tool, not unsupervised autonomy. It can control speed, steering, braking, lane changes, and intersections while following a navigation route. Drivers need not keep their hands on the wheel at all times, yet they must continuously monitor the road and be prepared to intervene immediately.

The sequence of EU recognitions began with the Netherlands in April and continued through Lithuania, Estonia, Denmark, Belgium, Slovenia, Czechia, Croatia, and Slovakia. Most have relied on mutual recognition of the single Dutch provisional approval rather than independent national testing.

These national clearances do not yet constitute bloc-wide authorization. An EU-wide decision requires a qualified majority in the Technical Committee on Motor Vehicles: at least 15 of 27 member states representing 65 percent of the EU population. Larger markets, like Germany, France, and Italy, remain under review, and a vote is expected this December.

However, for Latvian Tesla owners with compatible vehicles and software, the imminent rollout expands access to the supervised system while underscoring that attentive human oversight remains essential.

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