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SpaceX to replace Falcon 9’s titanium grid fins with steel on Starship’s Super Heavy booster
Following a question on Twitter about how SpaceX intends to manufacture the truly massive grid fins shown in renders of Starship’s Super Heavy booster, CEO Elon Musk revealed that SpaceX will build them out of welded steel.
For the first several years of Falcon 9 and Falcon Heavy booster recovery operations, SpaceX built grid fins – used for maneuvering the rockets at high speeds – out of aluminum. With Falcon 9 Block 5, aluminum grid fins were phased out entirely in favor of larger titanium fins, necessitated by exceptionally high-speed reentries that nearly melted through the aluminum fins on several occasions. Now, SpaceX wants to move from titanium to steel fins for its next-generation Starship launch vehicle.
Welded steel— Elon Musk (@elonmusk) October 3, 2019
In response to the Twitter user’s question, Musk simply stated that Super Heavy’s grid fins would be manufactured out of “welded steel”, certainly keeping with the CEO’s now well-known love for the material. In October 2018, Musk finally managed to convince most of the senior engineers reporting to him that – despite years of work and full-scale testing – SpaceX needed to radically redesign Starship.
Prior to this radical change, SpaceX had spent at least 2-3 years on a Starship design (formerly Big F_____ Spaceship; BFS) made almost entirely out of carbon fiber composites, an extremely lightweight material that can be optimized for high strength. However, as Musk ultimately concluded in late 2018, although carbon composites are undeniably light and strong (optimal for spaceflight), they have extremely low heat tolerance and can react violently with supercooled liquid oxygen. Built almost entirely out of aluminum alloys with similarly low melting points, Falcon 9 has also struggled with the challenges posed by material choices, made far more difficult by the need to recover and reuse orbital-class rocket stages.
Musk ultimately decided that redesigning Starship with steel (alloys with particularly high melting points and good strength) was the right way to go. According to Musk, the high-quality carbon fiber composites SpaceX was originally pursuing cost something like $130,000 per metric ton, translating to a truly gobsmacking cost – accounting for unavoidable wastage – of $400M-$500M or more just to buy the materials needed to build a single Starship and Super Heavy booster. Steel, on the other hand, is quite literally 50 times cheaper, costing SpaceX around $2500 per ton, or as little as $10M in structural materials for each ship/booster pair.
Man of Stainless Steel
Speaking at a September 28th presentation on the 2019 status of Starship’s design, CEO Elon Musk couldn’t praise his decision to move to stainless steel enough, describing it as likely being the single best design decision he has ever made. It remains to be seen if the eccentric self-taught engineer’s decision was the correct one, but the progress SpaceX has made in just 10-11 months is undeniable. SpaceX has gone from a nearly blank slate to Starhopper’s 150m (500ft) test flight in ~6 months and gone from nothing to Starship Mk1 in another 6 or so months.
According to Musk, the properties of stainless steel – mainly a high melting point/working temperature and a tendency to strengthen at cryogenic temperatures – mean that the relatively heavy material is able to produce a launch vehicle that could eventually be far lighter and higher-performance than one made with carbon composites (BFR) or aluminum alloys (Falcon 9). Thanks to those properties, Starship/Super Heavy will become much stronger when filled with cold propellant and will also require little to no external heat shielding on its leeward half, whereas a reusable Al/composite rocket would require major thermal protection on nearly all exposed surfaces.
As part of the move to remove any ultra-expensive nonessential materials from the designs of Starship and Super Heavy, Musk has apparently also turned his gaze on the booster’s grid fins. As described at the top of this article, SpaceX replaced Falcon 9’s aluminum grid fins with titanium fins, requiring the company to create the largest single-piece titanium casting in the world. Musk has repeatedly indicated that each grid fin is extremely expensive.
In light of their expense, Musk (or SpaceX) has seemingly decided that future (larger?) SpaceX rockets will try to avoid large, titanium castings. Super Heavy nevertheless still needs massive grid fins: official renders published by SpaceX last month revealed a new diamond shape for the booster’s fins, and Musk later took to Twitter to reveal that they would be made out of welded steel instead of titanium.
Based on SpaceX’s official 2019 Super Heavy renders, the booster’s grid fins measure approximately 7m by 3m (23 ft by 10 ft), dwarfing Falcon 9’s titanium fins (perhaps 2m by 1.2m) with something like 8-10 times the surface area. Although 301-series stainless steel has a melting point and heat capacity roughly 15% lower than Grade 5 titanium, its strength characteristics are otherwise similar, while also remaining mechanically functional at almost three times the working temperature of titanium (840C vs. 330C).
Most importantly, not only is 301 steel roughly 15-20 times cheaper than titanium, but the process of fabricating large steel components – particularly with welding instead of casting – is dramatically faster, easier, and cheaper than working with and forming titanium. With their reasonably similar properties and the increased size of Super Heavy, it’s likely that steel grid fins would exhibit little to no ablation during even the hottest atmospheric reentries, and it would nevertheless be extremely easy and cheap to either repair or replace fins in the unlikely event of damage.
Given just how quickly and relatively easily SpaceX has built full-scale flight hardware out of steel and assuming there are no technical showstoppers caused by changing scales, it wouldn’t be surprising in the slightest to see SpaceX fabricate and test welded steel grid fins on Falcon 9 boosters in the near future.
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Tesla Superchargers open to Lucid Air, but not without one key thing
Lucid’s full lineup of EVs is now able to use Tesla Superchargers in the United States and Canada.
Tesla Superchargers will be open to Lucid Air vehicles starting on July 31, a move that comes nearly two years after the companies agreed to terms that would allow them to partner.
Lucid joins a long list of EV makers that have a full lineup of EVs that can utilize Tesla’s extensive Supercharger Network across the United States and parts of Canada. In all, over 32,500 Tesla Superchargers will be accessible to Lucid owners at the end of the month.
Lucid NACS adoption ‘must have been a bitter pill to swallow’: Elon Musk
All Air models, regardless of year or trim level, will gain access to the entire North American Tesla Supercharger Network. It will just need one key thing to charge: an NACS adapter.
Lucid Air sedans will require a DC NACS to CCS1 adapter in order to enable charging at the Tesla stalls. These will be priced at $220 plus tax.
Emad Dlala, Senior VP of Powertrain at Lucid, said:
“In addition to offering the longest-range electric vehicle available, Lucid is committed to offering our customers seamless and wide access to public charging. Access to the Tesla Supercharging Network for the Lucid Air is yet another major milestone.”
Charging speeds will allow Air EVs to charge at up to 50 kW, gaining up to 200 miles of range per hour.
As for the Lucid Gravity, the company’s SUV, it will not require the adapter because of its native NACS port. It gained access to the Supercharger Network in January.
Although Lucid Airs will not be able to charge at the rate of some other vehicles, they do boast some of the best range ratings in the EV industry. Having the luxury of additional charging piles to access will increase the value of the long-range ratings Lucid offers with its vehicles.
Lucid joins several other automakers that have a full lineup of EVs that have access to the Tesla Supercharger Network:
- Ford
- Rivian
- General Motors (Chevrolet, GMC, Cadillac)
- Volvo
- Polestar
- Nissan
- Mercedes-Benz
- Hyundai
- Kia
- Genesis
- Honda
- Acura
- Aptera
Other brands, like BMW, Audi, Volkswagen, Porsche, and Subaru, are expected to gain access in the near future.
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Tesla Robotaxi wins over firm that said it was ‘likely to disappoint’
Tesla Robotaxi recently won over a Wall Street firm that had recently said the platform was “likely to disappoint.”
Tesla Robotaxi recently won over a Wall Street firm that had recently said the platform was “likely to disappoint.” The ride-hailing service has been operating for about a month, and driverless rides have been offered to a small group of people that continues to expand nearly every day.
JPMorgan went to Austin to test the Tesla Robotaxi platform, and it did so just a few weeks after listing Tesla as one of its “six stocks to short” in 2025. Highlighting the loss of the EV tax credit and labeling the Robotaxi initiative as one that was “likely to disappoint,” despite Tesla’s prowess in its self-driving software.
Analyst Ryan Brinkman has been skeptical of Tesla for some time, even stating that the company’s “sky-high valuation” was not in line with other stocks in the Magnificent Seven.
However, a recent visit to Texas that was made by JPMorgan analysts proved that the Robotaxi platform, despite being in its earliest stages, was enough for them to change their tune, at least slightly. The firm gave its props to the Tesla Robotaxi platform in a note by stating it was “certainly solid and felt like a safe ride at all times.”
It’s always nice to hear skeptics report positive experiences, especially as Robotaxi continues to improve and expand.
Tesla has already expanded its geofence for the Robotaxi suite in Austin, picking a very interesting shape for its newest boundaries:
Tesla’s Robotaxi expansion wasn’t a joke, it was a warning to competitors
As Robotaxi expands, Tesla is dealing with competition from Waymo, another self-driving ride-hailing service that is operating in Austin, among other areas. After Tesla’s expansion, which brought its accessible area to a greater size than Waymo’s, it responded by doubling its geofence.
Waymo’s expansion surpassed Tesla’s size considerably, and it seems Tesla is preparing to expand its geofence in the coming weeks.
Waymo responds to Tesla’s Robotaxi expansion in Austin with bold statement
The Robotaxi platform is not yet available to the public, but Tesla has been inviting more people to try it with every passing day. Currently, the map is roughly 42 square miles, but many believe Tesla is able to broaden this by a considerable margin whenever it decides.
Investor's Corner
Tesla needs to confront these concerns as its ‘wartime CEO’ returns: Wedbush
Tesla will report earnings for Q2 tomorrow. Here’s what Wedbush expects.
Tesla (NASDAQ: TSLA) is set to report its earnings for the second quarter of 2025 tomorrow, and although Wall Street firm Wedbush is bullish as the company appears to have its “wartime CEO” back, it is looking for answers to a few concerns investors could have moving forward.
The firm’s lead analyst on Tesla, Dan Ives, has kept a bullish sentiment regarding the stock, even as Musk’s focus seemed to be more on politics and less on the company.
However, Musk has recently returned to his past attitude, which is being completely devoted and dedicated to his companies. He even said he would be sleeping in his office and working seven days a week:
Back to working 7 days a week and sleeping in the office if my little kids are away https://t.co/77cc6sRCFZ
— Elon Musk (@elonmusk) July 20, 2025
Nevertheless, Ives has continued to push suggestions forward about what Tesla should do, what its potential valuation could be in the coming years with autonomy, and how it will deal with the loss of the EV tax credit.
Tesla preps to expand Robotaxi geofence once again, answering Waymo
These questions are at the forefront of what Ives suggests Tesla should confront on tomorrow’s call, he wrote in a note to investors that was released on Tuesday morning:
“Clearly, losing the EV tax credits with the recent Beltway Bill will be a headwind to Tesla and competitors in the EV landscape looking ahead, and this cash cow will become less of the story (and FCF) in 2026. We would expect some directional guidance on this topic during the conference call. Importantly, we anticipate deliveries globally to rebound in 2H led by some improvement on the key China front with the Model Y refresh a catalyst.”
Ives and Wedbush believe the autonomy could be worth $1 trillion for Tesla, especially as it continues to expand throughout Austin and eventually to other territories.
In the near term, Ives expects Tesla to continue its path of returning to growth:
“While the company has seen significant weakness in China in previous quarters given the rising competitive landscape across EVs, Tesla saw a rebound in June with sales increasing for the first time in eight months reflecting higher demand for its updated Model Y as deliveries in the region are starting to slowly turn a corner with China representing the heart and lungs of the TSLA growth story. Despite seeing more low-cost models enter the market from Chinese OEMs like BYD, Nio, Xpeng, and others, the company’s recent updates to the Model Y spurred increased demand while the accelerated production ramp-up in Shanghai for this refresh cycle reflected TSLA’s ability to meet rising demand in the marquee region. If Musk continues to lead and remain in the driver’s seat at this pace, we believe Tesla is on a path to an accelerated growth path over the coming years with deliveries expected to ramp in the back-half of 2025 following the Model Y refresh cycle.”
Tesla will report earnings tomorrow at market close. Wedbush maintained its ‘Outperform’ rating and held its $500 price target.
Tesla Superchargers open to Lucid Air, but not without one key thing
Tesla Robotaxi wins over firm that said it was ‘likely to disappoint’
Tesla needs to confront these concerns as its ‘wartime CEO’ returns: Wedbush
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