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SpaceX to put custom Starship propellant storage tanks through first trial

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5 years ago

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In the latest twist in the saga of SpaceX’s custom-built Starship launch pad propellant storage tanks, the company appears to have retroactively decided to build small prototype meant solely for testing.

Known as a ‘test tank,’ the relatively small steel structure was fairly rapidly assembled from parts of an older Ground Support Equipment (GSE) tank scrapped in July over the last week or so. SpaceX completed the first Starship-derived propellant storage tank in April 2021 and rapidly rolled that tank (GSE1) and a second (GSE2) from the build site to the orbital launch pad just a few weeks apart. Less than a month after that, SpaceX also completed GSE tank #3, though things seemingly devolved into chaos immediately thereafter.

Only three months later would GSE3 finally be transported to – and installed on a concrete mount at – Starship’s first orbital launch site, and only after a number of structural modifications and in the footsteps of GSE tanks #5 and #6. Little is known about why SpaceX’s custom GSE tank production faltered so soon after it began, why none of the five Starship-sized tanks installed at the orbital pad have been fully plumbed or subjected to any kind of testing, or why structural modifications were seemingly required after the fact. However, it’s safe to say that SpaceX’s brand new GSE ‘test tank’ is now at the center of the mystery.

Starship S20, test tank GSE4, and (half of) Super Heavy Booster 3. (NASASpaceflight – bocachicagal)

Thankfully, at minimum, the rapid appearance of SpaceX’s first GSE test tank returns some level of familiarity to the brief but chaotic history of Starship’s orbital launch pad propellant tanks. Test tanks are nothing new and have been an integral part of Starship development since Test Tank 1 first headed to SpaceX’s suborbital launch (and test) facilities in January 2020. In the 20 months since, SpaceX has built and tested seven small test tanks, several of which didn’t survive.

Whether intentionally destroyed or not, each test tank explicitly helped SpaceX qualify new manufacturing techniques, different materials, and different skin thickness and generally gather data more quickly and cheaply than full-scale prototypes would allow. Most recently, for example, SpaceX seemingly successfully tested a Super Heavy booster test tank, subjecting the prototype to cryogenic liquid nitrogen and using hydraulic rams to simulate the thrust of nine Raptor engines on an unproven disk-like thrust structure.

Now, almost as if SpaceX snapped out of a trance and remembered the utility of test tanks, the company has assembled a subscale GSE prototype presumably meant to verify that its custom-built propellant storage tanks can handle a set of conditions significantly different from the Starships they’re derived from. In this case, that GSE tank was quite literally built from scrapped sections of GSE tank #4. In fact, the top half (forward dome section) was quite literally cut off of GSE4 after the tank was scrapped last month for unknown reasons.

Over the last several months, while GSE tank production and installation took an unexpected hiatus, SpaceX workers slowly but surely welded steel rings (stiffeners) to the exterior of GSE1, GSE2, and GSE3. When GSE5 and GSE6 eventually headed to the pad, they left with those stiffeners already installed, implying that whatever tripped SpaceX up was likely structural. The GSE4 test tank also includes external stiffeners along each circumferential weld (where rings were stacked or domes joined).

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Test tank GSE4. (NASASpaceflight – bocachicagal)
SpaceX’s GSE tanks and their “cryo shells.” (NASASpaceflight – bocachicagal)

At the same time as SpaceX was (or wasn’t, for several months) building its own GSE tanks, contractors normally tasked with assembling water towers and storage tanks in situ built eight massive 12m (~40 ft) wide tanks of their own. Deemed “cryo shells,” much like their name suggests, those tanks are meant to fully enclose SpaceX’s GSE tanks. SpaceX will use those shells to insulate their thin, single-walled steel propellant tanks, thus keeping their cryogenic contents cryogenic for as long as possible. How they’ll be insulated is unclear, though.

Based on the seemingly retroactive decision to strengthen the exterior of those GSE tanks, the general consensus as of late is that SpaceX wants to pull at least a partial vacuum in the gap between shell and tank. It’s also possible that SpaceX will do the opposite and pressurize that gap (as much as possible) with an insulative gas like nitrogen. Extra confusion comes from the fact that Starship tanks are technically designed to support a literal spacecraft (operating in a near-total vacuum) without the need for external stiffeners.

Additionally, it’s fairly clear that SpaceX hasn’t built a custom subscale cryoshell or concrete installation pad for its GSE4 test tank, meaning that it will really only be useful for testing some of the loads operational GSE tanks will experience inside their sleeves. Additionally, given that SpaceX has already completed six of the orbital pad’s seven GSE tanks and all seven of their cryosleeves, the discovery of any significant issues during GSE4 testing could easily trigger months of rework and delays. With any luck, though, GSE4 will sail through an imminent test campaign, clearing the way for SpaceX to finish plumbing, sleeving, and activating Starship’s first orbital launch site tank farm.

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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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Elon Musk

Elon Musk and Trump are closer than ever, and Tesla could be the big winner

Elon Musk sat beside Trump as AI leaders signed a voluntary White House safety accord.

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2 hours ago

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September 29, 2026

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Elon Musk had the seat right next to President Donald Trump on Tuesday as the White House hosted the leaders of America’s biggest artificial intelligence companies for a lunch that ended with a voluntary industry accord on AI safety.

A seating chart Trump posted on Truth Social placed Musk at the president’s left in the East Room, with Nvidia CEO Jensen Huang on his right, according to an Associated Press reporter. Anthropic CEO Dario Amodei, OpenAI President Greg Brockman, Meta’s Mark Zuckerberg, Google’s Sundar Pichai, Microsoft’s Satya Nadella and Amazon founder Jeff Bezos also attended, along with Vice President JD Vance and House Speaker Mike Johnson.

After the lunch, Trump told reporters outside the West Wing that the executives had signed “The White House Accord on Superintelligence: A Joint Commitment on Frontier SI Responsibilities.” Johnson described it as a voluntary statement of principles built on “robust internal controls and layers of internal and external review,” while Zuckerberg said company boards would independently review reports from outside auditors. Trump called the document “morally binding,” said he would name a new AI czar within days, and signed an executive order formally renaming artificial intelligence “super intelligence,” CNBC reported.

Musk was not in the room for Tesla alone. Since SpaceX absorbed xAI, he runs the company behind Grok and one of the largest AI training operations anywhere. On September 25, he said another 220,000 Nvidia GB300 chips would come online at Colossus 2 within a week, with more expected in November and December.

SpaceX confirms third massive compute deal at Colossus data center

 

Musk also used the trip to restate his energy ambitions. “SpaceX is aiming together with Tesla to do 200 gigawatts of solar production per year,” he said at an event in Washington. It is the same combined target he laid out that feeds directly into Terafab, the Tesla and SpaceX chip venture that will need enormous amounts of power.

The showing between Musk and Trump has come a long way, since the two had the very public split in mid 2025 after Musk opposed the “Big Beautiful Bill” and left DOGE. They reconciled at Charlie Kirk’s memorial that September, and Trump later called their relationship “good”. Since then, Musk has joined Trump’s China delegation in May and attended last week’s White House state dinner for Chinese President Xi Jinping.

For Tesla, that access to government official could pay dividends. As Teslarati noted in January, federal autonomy rules, NHTSA oversight and a single national standard for driverless vehicles all run through an administration Musk can more easily reach directly as Tesla works to scale Robotaxi and Cybercab beyond Texas.

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Elon Musk

Tesla Roadster’s new patent preps white-knuckle speeds, keeping it grounded

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16 hours ago

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September 29, 2026

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Credit: @BLKMDL3/Twitter

Ahead of its highly anticipated unveiling, Tesla’s upcoming Roadster received a new patent that aims to keep it grounded while enabling white-knuckle speeds.

The patent, which was granted on September 29, is titled “Electric Car Fan,” bluntly stating its design but not its purpose, which is further detailed in the text of the application. Interestingly, it comes two weeks before the Roadster event, which was delayed due to unfavorable weather on Thursday, which could cause issues, as Tesla revealed the event must be held outdoors.

The purpose is to solve a problem that is relatively unique to high-performance electric cars. Instant motor torque is useless if the tires cannot plant that force, and conventional wings and underbody tunnels generate downforce only when air is already rushing past the car. At launch, in slow corners, and under hard braking from modest speed, passive aerodynamic additions contribute essentially very little to downforce.

Tesla’s filing says that its fans can produce the downforce needed, independent of vehicle velocity, then ease off so the same hardware does not pile on drag at highway speeds, an issue that can come from excessive body modifications.

The hardware outlined in the patent is a ducted-fan package that is placed into the rear of the vehicle. An underbody inlet between the rear wheels feeds a duct that rises to a wide outlet in the diffuser. In that outlet are four axial fans, which are divided by vertical strakes. They will pull air from under the floor and press the chassis onto the pavement.

The language in the patent claims it can cut drag rather than add to it while simultaneously increasing downforce.

Tesla Roadster event requires restricted airspace, and the FAA obliges

The fans run from the high-voltage battery and a vehicle control system, so output can be modulated rather than left on as a fixed penalty.

There are additional strengths that can come from this design, like extra tire load at low speed, which can contribute to even more face-melting acceleration rates, decrease stopping distance, and sharper turn-in before a wing has air to work with. Adjustable fan speed lets the car add grip only when needed, so it can be catered to the force of a turn or acceleration.

These designs were previously used, and banned, in some competitive settings. The Brabham BT46B was banned in F1 competition for using a similar fan design and being labeled as too effective.

Tesla still lists the Roadster as having a sub-two-second 0-60 MPH time and a 250-plus-MPH top speed, and there are expectations for a SpaceX cold-gas thruster package that could not only increase acceleration but potentially cause the vehicle to hover.

It is important to note that a patent is not a production part, and packaging four fans in a rear diffuser, managing noise, and potential debris are all things Tesla must consider. With that being said, the patent being granted shows Tesla is designing the Roadster to go fast, but it is also attempting to use unique strategies to combat any issues it might have at those speeds.

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Investor's Corner

Tesla showrooms picked clean ahead of Q3 end as demand looks strong

Published

17 hours ago

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September 29, 2026

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Credit: @thaichiminh1907/X

Tesla (NASDAQ: TSLA) showrooms have been picked clean ahead of the end of the third quarter of the year, as demand looks to be strong and delivery estimates for new vehicles are pushed into late 2026 and early 2027.

Tesla appears to have sold out of many of its Model 3 and Model Y trim levels in the United States, as only the Model Y RWD and Model Y All-Wheel-Drive are available for delivery before the end of the year.

Additionally, many showrooms are either completely empty or void of all but just one demo unit within the buildings themselves in an effort to bolster what could be one of Tesla’s best quarters in vehicle deliveries in recent memory.

Additionally, when I spoke to the guys at Tesla Mechanicsburg two weeks ago, when I returned the Model Y L, their third hauler of the week had just arrived, and every vehicle on it, along with every vehicle in their delivery lot, was accounted for and had a name attached to it for delivery.

Tesla saw a 25 percent increase in deliveries in Q2 compared to the same quarter the year before. The vast majority of the 480,126 units it delivered, 467,762 vehicles to be exact, were the Model 3 and Model Y.

In Q3 2025, Tesla delivered 497,099 vehicles, once again a figure that was dominated by the company’s two mass-market vehicles. Analysts have unusually wide predictions for this quarter, likely because so many firms missed the Q2 delivery figure by such a substantial margin; Wall Street predicted 408,000 cars, while Tesla delivered 480,000.

Goldman Sachs has Tesla slotted for 435,000 deliveries in Q3, while JPMorgan said it anticipates 482,000. The median guess is about 449,000 deliveries for Q3.

Interested in ordering a Tesla? Use my referral code for three free months of Full Self-Driving (Supervised) here.

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