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SpaceX outfits Starship prototype with unique Starlink satellite dispenser

The mouth of Starship S24's bizarre Starlink satellite 'dispenser' was properly revealed on March 24th. (NASASpaceflight - bocachicagal)

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After several weeks of work and occasional glimpses of the hardware and installation process, it’s now clear that SpaceX has outfitted part of its next Starship prototype with a truly unique Starlink satellite dispenser.

It remains to be seen if this particular assembly is simply a pathfinder – an experiment never meant for flight – or an integral part of a prototype that could become the first Starship to reach space or even orbit. In the first few months of 2022 a pathfinder with a much larger bay door was also quickly assembled but ultimately moved to the scrapyard. SpaceX’s latest payload bay prototype is quite different.

First, the device installed inside what appears to be the steel rings Starship S24’s nosecone will eventually be stacked on top of is almost nothing like any satellite deployment adapter observed in the past or present. The rectangular framework SpaceX craned inside of the barrel-like section of five steel rings – a cylinder measuring around 9m x 9m (30 ft x 30 ft) – about two weeks ago looked rudimentary and lacked any obvious moving parts, generating some ambiguity. Based on its apparent dimensions, the frame could likely extend anywhere from 10-15m (30-50 feet) up into Ship 24’s nosecone before the diameter would get too narrow for it to continue.

If it was a satellite deployment adapter, which most expected it to be, it was nothing like any other common adapter – including SpaceX’s own unusual present-day Starlink deployment method. It wasn’t until March 24th that SpaceX spun the nose barrel around, revealing an unusual cutout akin to a giant mail slot. At that point, it became clear that Ship 24’s nose had been fitted with a Starlink satellite deployment mechanism akin to a giant PEZ dispenser.

Ship 24’s Starlink dispenser was installed inside its nose barrel section on March 7th. (NASASpaceflight – bocachicagal)
Ship 24’s nosecone and nose barrel; March 24th. (NASASpaceflight – bocachicagal)
Later the same day, SpaceX spun the barrel around, revealing a bizarrely shaped cutout. (NASASpaceflight – bocachicagal)

Instead of a large, alligator-like payload bay, all Starship would need is a comparatively tiny slot and either an active or passive mechanical deployment mechanism. Starlink satellites would first be loaded one by one into the slot and somehow lifted inside the bay on the rail-like frame SpaceX recently installed. Eventually, that dispenser would be filled with a stack of an unknown number of Starlink satellites – likely larger Starlink V2 prototypes but possibly today’s smaller V1.5 satellite variant. Once in orbit, the stack of satellites would be ejected one by one through Starship’s payload slot. The satellites could potentially be passively fed down to the slot with a tension mechanism or Starship’s maneuvering thrusters, reducing the dispenser’s complexity.

SpaceX will almost certainly still develop a full actuating payload bay for Starship to take full advantage of all space it offers.

Crucially, alongside the first fully outfitted prototype with an upgraded Starship nosecone design, the ‘nose barrel’ the apparent Starlink dispenser is part of has also been fitted with heat shield stand-offs, ceramic wool insulation, and netting. Most importantly, technicians began installing dinner plate-sized heat shield tiles on the barrel section’s exterior within the last few days. The logic behind SpaceX’s Starbase decision-making has been increasingly indecipherable in recent months but, in theory, it would make little logical sense to waste time, effort, and money installing a thermal protection system (TPS) on a Starlink dispenser.

In other words, it’s quite likely that this Starlink dispenser is actually a part of Ship 24 flight hardware. Alongside Booster 7, Ship 24 is widely believed to be the first Starship scheduled to attempt an orbital launch after the recent demotion of Ship 20 and Booster 4. That means that it’s quite possible that this dispenser is actually meant to deploy Starlink satellites from Starship. According to Elon Musk, Ship 24 and Booster 7’s orbital test flight could occur as early as May 2022.

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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 eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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