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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 is using a redesigned Cybertruck battery cell to mitigate Semi challenges

It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.

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Tesla revealed that it is utilizing redesigned Cybertruck battery cells in its Long Range Semi to mitigate some pertinent challenges that come with long-haul logistics.

It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.

Tesla’s long-awaited Semi truck is entering production at its Nevada Gigafactory, and fresh factory footage reveals a clever evolution in its battery technology.

The Long Range variant, designed for up to 500 miles of real-world range, relies on a structural battery pack that uses the same 4680-form-factor cells found in the Cybertruck.

However, Tesla engineers have completely redesigned the pack’s architecture—shifting from the flat, pancake-style modules typical in passenger vehicles to a compact, vertical cubic layout. This change isn’t just about cramming more energy into the chassis; it’s a targeted solution to one of electric trucking’s biggest headaches: range loss in cold climates.

Dan Priestley, Head of the Tesla Semi program, said:

“We’re using essentially the same cell out of Cybertruck, but our cars packs are more like a pancake. Whereas these are more like a cube. You get a lot of energy stored in a small space. You can only do this if you design the vehicle to be electric from the ground up.”

In conventional EVs, battery packs are laid out horizontally in wide, flat arrays to fit under the floor. While this works for cars and even the Cybertruck’s structural pack, it exposes a large surface area to the elements.

Heat escapes quickly, especially overnight when the truck is parked. Cold temperatures slow chemical reactions inside lithium-ion cells, reducing available energy and forcing the vehicle to expend extra power warming the battery and cabin.

Real-world tests on vehicles like the Cybertruck show winter range losses of 20-40 percent, depending on conditions. For long-haul truck drivers operating in Canada, Scandinavia, or the northern U.S., this “silent killer” means unplanned stops, reduced payloads, and higher operating costs.

From personal experience, cold weather still impacts EV batteries even with various inventions and strategies that companies have come up with. In the cold Pennsylvania winter, charging was much more frequent for me due to range loss due to temperatures.

Tesla’s cubic battery pack flips the script. By arranging the 4680 cells in tall, dense vertical stacks, the pack minimizes external surface area relative to its volume—essentially turning the battery into its own thermal blanket.

Factory video from the Semi assembly line shows these large, yellow-green structural modules mounted directly onto the chassis, forming a near-cube shape.

The reduced exposure helps the pack retain heat generated during operation, keeping cells closer to their optimal temperature even after hours in sub-zero conditions.

The design doesn’t stop there. Tesla pairs the cubic pack with an advanced heat pump system that actively recycles thermal energy from the motors, brakes, and even ambient air.

Tesla reveals various improvements to the Semi in new piece with Jay Leno

Unlike passive systems in earlier EVs, this architecture transfers waste heat back into the battery, maintaining readiness for morning departures without draining the pack.

Executives have noted that the combination, cubic geometry plus intelligent thermal management, dramatically cuts overnight cooldown and range degradation, making the Semi viable for 24/7 fleet operations in harsh winters.

Beyond cold-weather performance, the redesigned pack integrates structurally with the truck’s frame, enhancing rigidity while simplifying assembly. Production footage shows workers installing the massive modules early in the line, signaling that the Semi’s battery is now a core chassis component rather than an add-on.

Using proven 4680 cells keeps costs down and leverages Tesla’s scaled manufacturing know-how from Cybertruck and Model Y lines.

Tesla’s focus on ramping up Semi output will lean on small innovative steps like this one. Truckers are not immune to traveling in cold weather conditions, and changes like this one will help make them more effective while also increasing output by logistics operators who choose to go all-electric with the Tesla Semi.

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SpaceX is keeping the Space Station alive again this weekend

SpaceX’s Falcon 9 launches Northrop Grumman’s Cygnus NG-24 to the ISS with 11,000 pounds of cargo Saturday.

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SpaceX is targeting April 11 for the launch of Northrop Grumman’s Cygnus XL cargo spacecraft to the International Space Station, carrying over 11,000 pounds of supplies, science hardware, and equipment for the Expedition 73 crew aboard. Liftoff is set for 7:41 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available April 12 at 7:18 a.m. ET.

The mission, officially designated NG-24 under NASA’s Commercial Resupply Services program, names its spacecraft the S.S. Steven R. Nagel in honor of the NASA astronaut who flew four Space Shuttle missions and logged over 723 hours in space before his death in 2014. Unlike SpaceX’s own Dragon capsule, which docks autonomously, Cygnus relies on NASA astronauts to capture it using a robotic arm before it is berthed to the space station’s module for unloading. When the mission wraps up around October, the Cygnus will depart loaded with station trash and burn up on reentry.

Countdown: America is going back to the Moon and SpaceX holds the key to what comes after

This is the second flight of the Cygnus XL configuration, which debuted on NG-23 in September 2025 and offers a roughly 20% increase in cargo capacity over the previous design. Northrop Grumman switched to Falcon 9 launches after its own Antares 230+ rocket was retired in 2023 following supply chain disruptions from the war in Ukraine.

The upcoming cargo includes a new module to advance quantum research, and an investigation studying blood stem cell production in microgravity with potential therapeutic applications on Earth.

The NG-24 mission is one piece of a much larger picture for SpaceX and the U.S. government. As Teslarati reported, SpaceX has become an indispensable launch provider for U.S. national security missions, picking up a $178.5 million Space Force contract in April 2026 to launch missile tracking satellites, while also holding roughly $4 billion in NASA contracts tied to the Artemis lunar program.

At a time when no other American rocket can match the Falcon 9’s combination of reliability, cost, and launch cadence, Saturday’s mission is a straightforward reminder of how much the U.S. government now depends on a single commercial provider to keep its astronauts supplied and its satellites flying.

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Tesla hits FSD hackers with surprise move

In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.

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Tesla is cracking down on hackers who have figured out a way to utilize third-party programs to activate Full Self-Driving (FSD) in their vehicles — despite the suite not being approved for use in their country.

Tesla has launched a sweeping enforcement campaign against owners using third-party hardware hacks to activate FSD software in countries where the advanced driver-assistance system remains unregulated or unapproved.

In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.

Reports of the crackdown have surfaced across Europe, China, Japan, South Korea, and the UK, marking a significant escalation in Tesla’s efforts to enforce regional software restrictions.

FSD is Tesla’s flagship supervised autonomy package, which is available in several countries across the world. Currently limited by regulatory hurdles, it has not received full approval in most markets outside of the United States due to various things, such as safety standards, data privacy, and local traffic laws.

However, the company is working to expand its availability globally. Nevertheless, Tesla has installed the necessary hardware on vehicles globally, but locks the features based on geographic location.

Some owners have taken accessing FSD into their own hands, using jailbreak or bypass devices.

These “jailbreak” tools, typically €500 USB-style modules that plug into the vehicle’s Controller Area Network (CAN) bus, intercept signals to spoof approvals and unlock FSD, including advanced navigation, Autopark, and Summon features.

Hackers in Poland, Ukraine, and elsewhere have distributed the devices, with some claiming they work on HW3 and HW4 vehicles and can be unplugged to restore stock settings. In China alone, over 100,000 owners reportedly installed such modifications.

Tesla’s response has been swift and uncompromising. Recently, the company began sending in-car notifications and emails warning owners that unauthorized modifications violate terms of service, compromise vehicle safety systems, and expose cars to cybersecurity risks.

The email communication read:

“Your vehicle has detected an unauthorized third-party device. As a precaution, some driver assistance functions have been disabled for safety reasons. A software update will be available soon. Once you install the update, some features may be enabled again.”

Vehicles detected using the hacks have had FSD capabilities remotely disabled without refund. In some cases, owners report permanent bans, even if they had legitimately purchased the software package.

Tesla’s hardline stance underscores its commitment to regulatory compliance and safety.

Tesla has long argued that unsupervised FSD requires rigorous validation, and premature activation could endanger drivers and bystanders.

The crackdown sends a clear-cut message to those who are bypassing the FSD safeguards, but there are greater implications for Tesla if something were to go wrong. This is an understandable way to protect the company’s reputation for its FSD suite.

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