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SpaceX Starship prototype in limbo after engine test lights rocket on fire

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The fate of SpaceX’s fourth full-scale Starship prototype appears to be in limbo after a third (seemingly successful) engine ignition test unintentionally caught the rocket on fire.

Now more than 12 hours after Starship SN4 fired up its new Raptor engine, the ~30m (~100 ft) tall, 9m (~30 ft) wide prototype is apparently trapped with one or both of its propellant tanks still partially filled with liquid (or gaseous) methane and/or oxygen. An initial road closure scheduled from noon to 6pm local quickly came and went and SpaceX and Cameron County Texas have since modified the paperwork, extending the closure a full 24 hours. In other words, SpaceX has reason to believe that Starship SN4 may continue to be unsafe (i.e. pressurized) as many as ~30 hours after it technically completed its third static fire test – extremely unusual, to say the least.

There’s only one obvious conclusion to draw. Whether it was something invisible to the public eye or damage related to the off-nominal fire that burned for some 15 minutes after Raptor shut down, SpaceX appears – to some extent – to have lost control of Starship SN4.

At the moment, it’s unclear what is wrong and what SpaceX is attempting to do to resolve the problem. Based on photos of Starship SN4 taken before the fire, there is good news and bad news from what can be publicly ascertained. Controlled from the ground by unprotected wires strung up and down the rocket and connected at its base, the uncontrolled fire that burned in at least two locations around Starship’s aft may have severed some or all of those critical connections.

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Starship SN4’s third successful Raptor test caused a secondary fire that has put the vehicle in a state of limbo. (LabPadre)

That would render Starship – potentially perfectly healthy and operational – almost entirely uncontrollable, while also potentially removing SpaceX’s access to telemetry. In other words, the company may currently have no idea how pressurized all or part of Starship SN4 is and may also have little to no control of some or all of the rocket. For that to be true, Starship SN4 would, however, have to have less than fully redundant control hardware. To perform hops, for example, the ship would need both wired and radio links capable of sending telemetry and receiving commands to remain both on the ground and after liftoff.

It’s possible that Starship SN4 has the necessary hardware installed but that it wasn’t activated for the static fire test (think “Starship will never leave the ground, why would we need to enable wireless controls?”). It’s also possible that the blown pipe and methane leak that appeared to cause the secondary fire damaged crucial propellant management hardware (valves, pumps, etc.) or was just a symptom of an even worse overpressure event that damaged or destroyed multiple such systems.

Given that safety is almost certainly the priority, chances are that some combination of fairly mild hardware failure and telemetry/control loss has left SpaceX with just enough uncertainty that it can’t risk sending technicians to the launch site to inspect the damage and reestablish control. As a result, the only option left is to quite literally sit and wait until it’s once again safe to approach the rocket. Thankfully, at this point, the risk of the mystery problem actually destroying Starship SN4 is very low. If, as it appears, only its methane tank is affected, leaving some unknown quantity of latent liquid methane trapped inside, it’s possible that waiting will actually solve the problem and safe the rocket.

Starship SN4 is pictured a few hours before its ill-fated third static fire test. (NASASpaceflight – bocachicagal)
On a positive note, it appears that the concerning amount of dark smoke created in the first minute or two of the post-test fire was caused by a huge amount of tape/insulation/???? wrapped around part of Starship’s test stand in the hours before its May 19th test attempt.(NASASpaceflight – bocachicagal)

The fact that Starship hasn’t exploded yet strongly implies either that the amount of propellant trapped is minuscule or that the vast majority of SN4’s propellant management systems (including vents) remain functional. Assuming that’s the case, any remaining cryogenic propellant will eventually boil into gas, increasing the pressure inside Starship’s tanks, while those tanks will continue to vent to prevent an explosion or rupture. Eventually, Starship SN4 will be empty once again and SpaceX will be able to approach the rocket to regain control and begin inspections and repairs.

Regardless, after such an unintentionally eventful static fire test, it’s extremely unlikely that SN4 will be ready for its inaugural flight test within the next few days. Stay tuned for updates as SpaceX works to regain control over the fourth full-scale Starship prototype.

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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 intertwines FSD with in-house Insurance for attractive incentive

Every mile logged under FSD now carries a documented financial value—lower risk, lower cost—based on Tesla’s internal driving data rather than external crash statistics alone.

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tesla interior operating on full self driving
Credit: TESLARATI

Tesla intertwined its Full Self-Driving (Supervised) suite with its in-house Insurance initiative in an effort to offer an attractive incentive to drivers.

Tesla announced that its new Safety Score 3.0 will automatically have a perfect score of 100 with every mile driven with Full Self-Driving (Supervised) enabled.

The change is designed to boost customers’ average safety scores and deliver noticeably lower monthly premiums.

The move marks the clearest link yet between Tesla’s autonomous driving technology and its proprietary insurance product. Tesla Insurance already relies on real-time vehicle data—such as acceleration, braking, following distance, and speed—to calculate a Safety Score between 0 and 100. Higher scores have long translated into cheaper rates.

Under the previous system, however, even brief manual interventions could drag down the average, frustrating owners who rely heavily on FSD. Version 3.0 eliminates that penalty for supervised autonomous miles, effectively treating FSD-driven segments as the safest possible driving behavior.

The incentive is immediate and financial. Drivers who keep FSD engaged for the majority of their trips will see their overall score rise, potentially shaving hundreds of dollars off annual premiums.

Tesla framed the update as a direct response to customer feedback, many of whom had complained that the old scoring model punished the very behavior it was meant to encourage.

For now, the program applies only to new policies in six states: Indiana, Tennessee, Texas, Arizona, Virginia, and Illinois.

Existing policyholders are not yet included, a point that drew swift questions from the Tesla community. Many owners in other states, including California and Georgia, expressed hope that the benefit would expand nationwide soon.

The announcement arrives as Tesla continues to roll out FSD Supervised updates and push for regulatory approval of more advanced autonomy. By tying insurance savings directly to FSD usage, the company is putting its own actuarial weight behind the technology’s safety claims.

Every mile logged under FSD now carries a documented financial value—lower risk, lower cost—based on Tesla’s internal driving data rather than external crash statistics alone.

Tesla has not disclosed exact premium reductions or the full rollout timeline beyond the six launch states.

Still, the message is clear: the more drivers trust FSD Supervised, the more Tesla Insurance will reward them. In an era when legacy insurers remain cautious about autonomous tech, Tesla is betting that its own data will prove the safest miles are the ones driven hands-free.

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Tesla finalizes AI5 chip design, Elon Musk makes bold claim on capability

The Tesla CEO’s words mark a strategic shift. Tesla has long emphasized software-hardware co-design, squeezing maximum performance from every transistor. Musk previously described AI5 as optimized for edge inference in both Robotaxi and Optimus.

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Credit: Elon Musk | X

Tesla has finalized its chip design for AI5, as Elon Musk confirmed today that the new chip has reached the tape-out stage, the final step before mass production.

But in a brief reply on X, Musk clarified Tesla’s AI hardware roadmap, essentially confirming that the new chip will not be utilized for being “enough to achieve much better than human safety for FSD.”

He said that AI4 is enough to do that.

Instead, the AI5 chip will be focused on Tesla’s big-time projects for the future: Optimus and supercomputer clusters.

Musk thanked TSMC and Samsung for production support, noting that AI5 could become “one of the most produced AI chips ever.” Yet, the key pivot came in his direct answer: vehicles no longer need the bleeding-edge silicon.

Existing AI4 hardware, which is already deployed in hundreds of thousands of HW4-equipped Teslas, delivers safety metrics superior to human drivers for Full Self-Driving. AI5 will instead accelerate Optimus robot development and massive Dojo-style training clusters.

The Tesla CEO’s words mark a strategic shift. Tesla has long emphasized software-hardware co-design, squeezing maximum performance from every transistor. Musk previously described AI5 as optimized for edge inference in both Robotaxi and Optimus.

Now, with AI4 proving sufficient, the company avoids costly retrofits across its fleet while redirecting next-generation compute toward higher-value applications: dexterous robots and exponential training scale.

But is it reasonable to assume AI4 enables unsupervised self-driving? Yes, but with important caveats.

On the hardware side, the claim is credible. Tesla’s FSD stack runs end-to-end neural networks trained on billions of miles of real-world data. Internal safety data reportedly shows AI4-equipped vehicles already outperforming average human drivers by a significant margin in controlled metrics (collision avoidance, reaction time, edge-case handling).

Dual-redundant AI4 chips provide ample headroom for the driving task, leaving bandwidth for future model improvements without new silicon. Musk’s assertion aligns with Tesla’s pattern of over-provisioning compute early, then optimizing ruthlessly, exactly as HW3 once sufficed before HW4 scaled further.

Unsupervised autonomy, meaning Level 4 or higher, is not solely a compute problem. Regulatory approval remains the primary gate.

Even if AI4 achieves “much better than human” safety statistically, agencies like the NHTSA demand exhaustive validation, liability frameworks, and public trust.

Tesla’s supervised FSD has shown rapid gains in recent versions, yet real-world edge cases, like construction zones, emergency vehicles, and adverse weather, still require driver intervention in many jurisdictions. Competitors like Waymo operate limited unsupervised fleets, but only in geofenced areas with extensive mapping. Tesla’s vision-only, fleet-scale approach is more ambitious—and harder to certify globally.

In short, Musk’s post is both pragmatic and bullish. AI4 is likely capable of unsupervised FSD from a technical standpoint. Whether regulators and consumers agree, and how quickly, will determine if Tesla’s bet pays off.

The company’s capital-efficient path keeps existing cars relevant while pouring future compute into robots. If the safety data holds, unsupervised autonomy could arrive sooner than many expect.

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Elon Musk signals expansion of Tesla’s unique side business

Long envisioning the Tesla Diner as more than a charging stop, Musk has clearly adopted the idea that the Supercharger and Restaurant combo is a good thing for the company to have. It’s a blend of classic American drive-in culture with futuristic Tesla flair, complete with a 1950s-inspired design, movie screens, and on-site dining.

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tesla diner
Credit: Tesla

Elon Musk has signaled an expansion of Tesla’s unique side business, something that really has nothing to do with cars or spaceships, but fans of the company have truly adopted it as just another one of its awesome ventures.

Musk confirmed on Wednesday that Tesla would build a new Diner location in Palo Alto, Northern California. After hinting last October that it “probably makes sense to open one near our Giga Texas HQ in Austin and engineering HQ in Palo Alto,” it seems one of those locations is being set into motion.

Long envisioning the Tesla Diner as more than a charging stop, Musk has clearly adopted the idea that the Supercharger and Restaurant combo is a good thing for the company to have. It’s a blend of classic American drive-in culture with futuristic Tesla flair, complete with a 1950s-inspired design, movie screens, and on-site dining.

He first floated broader expansion plans shortly after the LA opening in July 2025, noting that if the prototype succeeded, Tesla would roll out similar venues in major cities worldwide and along long-distance Supercharger routes.

Earlier hints included a confirmed second site at Starbase in Texas, tied to SpaceX operations, underscoring the Diner’s role in enhancing Tesla’s ecosystem behind vehicles.

The Los Angeles location on Santa Monica Boulevard in West Hollywood has served as a high-profile test case. Opened in July 2025 at 7001 Santa Monica Blvd., it features the world’s largest urban Supercharging station with 80 V4 stalls open to all NACS-compatible EVs, over 250 dining seats, rooftop views, and 24/7 service.

The retro-futuristic building replaced a former Shakey’s and quickly became a destination. Tesla reported selling 50,000 burgers in the first 72 days—an average of over 700 daily—drawing crowds with Cybertruck-shaped packaging, breakfast extensions until 2 p.m., and movie screenings.

Palo Alto stands out as a logical next step for several reasons. As Tesla’s longstanding engineering headquarters in the heart of Silicon Valley, the city is home to thousands of Tesla employees, engineers, and executives who could benefit from a convenient, branded gathering spot.

The area boasts high EV adoption rates, dense tech talent, and heavy traffic along key corridors, making a large Supercharger-diner an ideal fit for both daily commuters and long-haul travelers.

Proximity to Stanford University and the innovation ecosystem would amplify its appeal, potentially serving as a showcase for Tesla’s vision of integrated mobility and lifestyle experiences. It could be a great way for Tesla to recruit new talent from one of the country’s best universities.

If Tesla and Musk decide to move forward with a Palo Alto diner, it would build directly on the LA prototype’s momentum while addressing Musk’s earlier calls for expansion near core Tesla hubs.

Whether it materializes as a full confirmation or evolves from these hints remains to be seen, but the pattern is clear: Tesla is testing ways to make charging stops memorable. For EV drivers and enthusiasts alike, a Silicon Valley outpost could blend cutting-edge tech with nostalgic comfort, further embedding Tesla into everyday culture. As Musk’s comments suggest, the future of the Diner looks promising.

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