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SpaceX outfits Starship, Super Heavy with dozens of Raptor engines

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New photos shared by SpaceX show that the company has nearly finished installing a total of 39 upgraded Raptor engines on a new Starship and its Super Heavy booster.

Those prototypes – known as Ship 24 and Booster 7 – could be tasked with supporting Starship’s first orbital launch attempt sometime later this year if both make it through upcoming test campaigns without major issues. Whether that’s a probable outcome is still uncertain but recent progress suggests that it won’t take long for the prospects of both prototypes to shift into clearer focus.

After several rounds of proof testing and two trips to and from SpaceX’s Starbase, Texas orbital launch site (OLS) in March, April, and May, Super Heavy Booster 7 (B7) made its third trip to the pad on June 23rd.

“SpaceX used the six weeks Booster 7 spent back in a factory assembly bay to finish installing aerocovers, surfaces known as chines or strakes, car-sized grid fins, Starlink internet dishes, and – most importantly – 33 upgraded Raptor V2 engines. Combined, Booster 7 could produce up to 7600 metric tons (~16.8M lbf) of thrust at or before liftoff. Crucially, SpaceX also finished installing most of Booster 7’s Raptor heat shield in the same period, completing in six weeks work that took Booster 4 closer to half a year. With its heat shield and all 33 Raptors mostly in place, Booster 7 should be ready to kick off static fire testing almost as soon as it’s installed on Starbase’s orbital launch mount.”

Teslarati.com – June 24th, 2022

Booster 7 awaits its next round of tests. (NASASpaceflight – bocachicagal)

Building, qualifying, shipping, and installing 33 new Raptor 2 engines on Super Heavy B7 was already an impressive achievement and produced the most (potentially) powerful rocket booster ever assembled. On July 2nd, a pair of photos published by SpaceX showed off Booster 7’s nearly-finished engine section and simultaneously revealed that the company has finished installing all six of Starship S24’s Raptor engines – and even part of the ship’s aft thermal protection.

Differences are already visible between Ship 24 and Ship 20, the only other Starship prototype to have six Raptors installed. The most notable change is the addition of a metal framework that covers the entire breadth of the ship’s aft – most likely destined to support flat sections of insulation and thermal protection that will partially seal off sensitive engine, plumbing, pressure vessels, and avionics components located inside Starship’s aft. That extra shielding should help limit the extreme conditions that hardware will be subjected to during ground testing and, perhaps, in flight.

Ship 20, August 2021. (SpaceX – Elon Musk)
Ship 24, July 2022. (SpaceX)

Super Heavy Booster 7 has already completed a significant amount of testing, including four cryogenic proofs (cryoproofs) and one Raptor thrust simulation test. Since its third return to the pad, SpaceX has several more ambiguous tests, none of which appeared to involve cryogenic propellant loading. It’s possible that those tests focused more on Booster 7’s pressurization system, perhaps filling its tanks with the hot oxygen and methane gases it will eventually use to pressurize its tanks. It’s likely that SpaceX wants to put Booster 7 through at least one successful wet dress rehearsal – using real liquid methane and oxygen propellant – before attempting to static fire any of its 33 Raptors. Booster 7’s aft thermal protection system also isn’t entirely complete, so technicians will need to finish installing several more panels before any static fire testing.

SpaceX technicians handle one of the dozens of heat shield panels that will eventually protect Super Heavy B7’s Raptors from themselves. (NASASpaceflight – bocachicagal | July 3rd, 2022)

Alongside B7, Starship S24 has completed a good amount of cryoproof and Raptor thrust simulation testing, which it survived without any irreperable issues. The ship was then returned to an assembly bay on June 9th, where where workers have been installing heat shield tiles, finalizing the ship’s engine section, and completing dozens of other less visible closeout tasks. SpaceX also recently finished modifying one of its two suborbital test and launch mounts for Starship static fire testing, leaving the other mount semi-permanently modified for cryoproof and thrust simulation testing of future prototypes.

SpaceX has requested permission for road closures – each a potential 12-hour test window – on July 5th, 6th, 7th, 11th, and 12th.

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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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