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SpaceX tweaks Starship's Super Heavy rocket booster as design continues to evolve
CEO Elon Musk says that SpaceX continues to evolve the design of its next-generation Starship spacecraft and Super Heavy rocket booster, a process of continuous improvement the company has successfully used for a decade.
Designed to place more than 100 metric tons (220,000 lb) of payload into Low Earth Orbit (LEO), Starship would effectively double (and possibly triple) the expendable performance of SpaceX’s existing Falcon Heavy rocket. Critically, it would be able to dramatically outclass Falcon Heavy (and Falcon 9 even more so) in a fully reusable configuration, meaning that both the Starship upper stage and Super Heavy booster could be recovered and reused.
Since SpaceX first publicly revealed its next-generation launch vehicle and Mars ambitions in September 2016, the path to realizing the dream of a fully-reusable super heavy-lift launch vehicle has been decidedly windy. After making the radical decision to move entirely from carbon composites to stainless steel in late 2018, the Starship design has remained relatively similar, coalescing around a specific concept that has matured to full-scale tank tests. Now, Musk says that Super Heavy’s design was tweaked slightly to make the booster even taller than before, while he later noted that Starship’s design also continues to “[evolve] rapidly.”
According to Musk, the Super Heavy booster will be stretched by a steel ring or two, reaching a new height of ~70m (230 ft). In other words, Starship’s first stage alone will measure as tall as the entirety of a Falcon 9 or Falcon Heavy rocket – first stage, second stage, and payload fairing included. Powered by up to 37 Raptor engines, a Super Heavy booster could produce more than ~90,000 kN (19,600,000 lbf) of thrust at liftoff – an incredible 12 times as much thrust as SpaceX’s workhorse Falcon 9 rocket.
Starship, meanwhile, will be a beast of an orbital-class upper stage on its own, measuring at least 50m (165 ft) tall and weighing some 1350 metric tons (3 million lb) fully-fueled. Stacked on top of Super Heavy, a Starship ‘stack’ would reach a staggering 120m (395 ft) and weigh more than 5000 metric tons (11 million lb) once loaded with liquid oxygen and methane propellant.
In simple terms, Starship/Super Heavy should be the tallest, heaviest, and most powerful launch vehicle ever assembled once it heads to the launch pad for the first time. While SpaceX is making great daily progress its ever-growing South Texas rocket factory, built up from next to nothing in a matter of months, it could still be quite some time before that milestone is within reach.
SpaceX’s process of continuously tweaking and improving the design and production of its rockets does typically have that effect. However, it’s more a symptom of the company’s approach to hardware and software development. Instead of working slowly and carefully from nothing to a preconceived finished product, SpaceX typically seeks to design, build, and test the minimum viable product, gradually improving (or entirely replacing) past ideas, designs, and hardware until overarching goals are fully achieved.
With Falcon 9 and Falcon Heavy, this meant beginning with Falcon 1, a dead-simple proof-of-concept rocket. After successfully reaching orbit, SpaceX expanded its Falcon 9 development program, itself focused initially on the minimum viable product – a full-scale expendable rocket. Since Elon Musk founded SpaceX in 2002, the goal has always been to build a fully-reusable rocket – the company has simply chosen the far more sustainable and practical approach of tackling only a select few problems at a time.
The Starship and Falcon development programs aren’t directly comparable but it’s safe to say that Starship is currently still in the very early stages of hardware development. Shortly after revealing Super Heavy’s height growth, Musk noted that Starship’s design is also being tweaked.
Sketching out a rough series of upgrades that could feasibly be made to the reusable spacecraft’s currently design, Musk thinks that Starship’s conical tank domes (and thus Super Heavy’s, too) could be flattened. That might allow an extra ~3m (10 ft) of propellant tank space to be squeezed into the same 50m Starship length, improving performance by simply using the vehicle’s fixed volume more efficiently.
With a nascent factory quite literally churning out Starship hardware, these tweaks are a whole different animal. Thanks to data and insight gathered from testing actual full-scale Starship tanks, up to and including fully-assembled tank sections, SpaceX will be able to guide its continuous improvement with even greater precision, honing in on the next-generation rocket’s orbital launch debut.
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Elon Musk
SpaceX’s next Starship launch is about to attempt its biggest leap yet
SpaceX targets September 22 for Starship Flight 14, its first attempt to reach real orbit.
SpaceX has set September 22 as the target date for Starship’s 14th test flight, and this one carries a different goal than any of the 13 that came before it. Every previous Starship mission has intentionally flown a suborbital arc, reentering the atmosphere within the same hour it launched. Flight 14 is designed to send the craft into a genuine orbit around Earth for the first time.
The launch window opens at 7:15 a.m. Central time at Starbase in South Texas and runs for 75 minutes, pending regulatory approval, according to SpaceX’s mission description published Tuesday. If the flight goes as planned, Starship will circle the planet roughly six times at an altitude near 275 kilometers over about ten hours before a deorbit burn sends it toward a splashdown in the Pacific Ocean west of Chile, a departure from the Indian Ocean recoveries used on the last several flights.
The mission also marks the first attempt to put a working batch of Starlink V3 satellites into actual service. Flight 13 carried 20 of the new satellites in July, but because that mission never left a suborbital trajectory, the payload reentered along with the ship instead of separating into orbit.
SpaceX tells the FCC that Starship Flight 14 is going to orbit
Each V3 satellite is rated for roughly one terabit per second of downlink capacity, so a successful deployment on Flight 14 would be SpaceX’s largest single jump in network bandwidth since Starlink began flying on Falcon 9.
Flight 13 still did the heavier lifting on the technical side. That July mission flew a deliberately more stressful reentry profile to test Starship’s heat shield, and the ship survived its softest splashdown yet, intact enough for drone inspections shortly after landing. Elon Musk said the flight delivered “all the heat shield data we needed and then some,” a result Teslarati covered in detail when he later said SpaceX had solved the vehicle’s biggest reusability challenge. Flight 14 is where SpaceX starts spending that confidence on an actual orbital insertion rather than another controlled fall back to Earth.
One thing Flight 14 will not attempt is a tower catch of the ship. Musk floated the idea right after Flight 13, but walked the timeline back in August, saying a catch attempt was more likely “in a few months.” The Super Heavy booster will still aim for its own recovery, targeting an offshore landing point in the Gulf of America, the same approach used on recent flights.
September 22 is SpaceX’s own target, not a locked date. Starship’s schedule has slipped before over hardware readiness and FAA sign off, and the company has said as much in its own mission notes. But the plan itself represents the clearest marker yet that Starship is moving from a suborbital test program into something meant to carry paying payloads and, eventually, people.
Elon Musk
Elon Musk gives his most telling Tesla-SpaceX merger conversation yet
Elon Musk hinted a Tesla-SpaceX merger could be coming, and Wall Street is taking notice.
Elon Musk gave his clearest signal yet that Tesla and SpaceX could eventually combine, telling the All-In Summit in Los Angeles that the two companies’ deepening collaboration makes the question worth asking. Sawyer Merritt first surfaced the highlight on X Tuesday.
Asked directly why Tesla and SpaceX remain separate given how closely they already work together, Musk told hosts at the summit: “Great question there. With all this collaboration, on so many levels, who can imagine what action one might take when there’s so much close collaboration in so many areas.” SpaceX President Gwynne Shotwell, who joined Musk on stage, added that SpaceX personnel have already moved into xAI to fill leadership and engineering gaps, saying the businesses are integrating “faster than I thought,” though “not fully integrated yet,”
The comments landed on top of merger speculation that has been building on Wall Street for months. JPMorgan has called a tie-up “strategically coherent on paper,” pointing to overlapping ambitions in AI, robotics, energy, transportation and space. Jefferies went further, estimating Musk could retain roughly 55.3 percent voting control in a deal structured without a premium, a scenario that would still leave room for Tesla shareholders to come out ahead. On Kalshi, traders now put the odds of a merger before 2028 at 66 percent.
Tesla’s stake in SpaceX, still under one percent, traces back to its earlier investment in xAI, which converted to SpaceX equity after SpaceX absorbed the AI company. The two are also jointly building Terafab, a chip facility in Austin meant to serve both Tesla’s AI computing needs and SpaceX’s satellite ambitions. Wedbush analyst Dan Ives has stood by a 2027 merger timeline for months, and Cathie Wood’s ARK Invest recently floated a similar case, an idea Musk pushed back on directly at the time.
Another Tesla SpaceX merger prediction by ARK Invest has Elon Musk talking
The timing adds another layer. Tesla has scheduled an October 1 unveiling for its next generation Roadster at a venue near SpaceX’s McGregor, Texas test site, using the phrase “Go for launch” in its promotional material. Both stocks dipped roughly 2 percent Monday before recovering slightly in premarket trading Tuesday, with SpaceX shares up about 0.4 percent and Tesla essentially flat.
Musk stopped short of confirming anything is in motion. But unlike his past denials of a corporate restructuring, this response didn’t rule one out, and it came with Shotwell sitting next to him describing an integration that’s already underway.
The Tesla Roadster unveiling is getting hyped up by the company’s CEO Elon Musk, who has been a big reason the product has such high expectations due to delayed timelines and a constant need to make it even more insane than before.
Tesla announced on September 12 that it would officially unveil the Roadster in Waco, Texas, on October 1, ending years of patience for fans and reservation holders who have waited for the all-electric supercar to enter production since 2017.
Musk has said that this event will be well worth the wait on several occasions, and last year on the Joe Rogan Experience, he said that there should be a closing chapter to supercars- the end of cars that aren’t focused on safety.
He said:
“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one. I think it has a shot at being the most memorable product unveil ever. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”
Musk’s teases have continued, and now that the event is roughly two weeks away, it seems like Roadster is finally going to show up and blow some minds:
It’s out of this world
— Elon Musk (@elonmusk) September 13, 2026
Excitement guaranteed
— Elon Musk (@elonmusk) September 13, 2026
Tesla has definitely dragged out the development of the Roadster, but there is a good reason for it.
Tesla has been working on many other projects, most notably self-driving efforts to increase passenger safety, and those simply took priority over the Roadster, a low-volume, high-performance sports car that has a lightning-fast acceleration rate of 0-60 MPH in just 1.1 seconds, could potentially fly, and contributes very little to the company’s mission.
However, many people have the Roadster on pre-order through the referral program or with their own money, and it is time that Tesla delivers on that.
SpaceX’s next Starship launch is about to attempt its biggest leap yet
Elon Musk gives his most telling Tesla-SpaceX merger conversation yet
