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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 bolsters Referral Program with big change and bigger rewards
The Tesla Referral Program offers benefits to both car buyers and existing Tesla owners, including complimentary Full Self-Driving trials, free Supercharging miles, and discounts on select purchases, such as cars.

Tesla has bolstered its Referral Program by offering more significant benefits for both the referrer and the referee. However, it only applies to certain vehicles in the Tesla lineup.
The Tesla Referral Program offers benefits to both car buyers and existing Tesla owners, including complimentary Full Self-Driving trials, free Supercharging miles, and discounts on select purchases, such as cars.
It changes relatively frequently, and is a great way to encourage people to buy a new car. Tesla is routinely making adjustments to it to stimulate demand, but the referral program likely does not encourage too many sales. Instead, it’s more of a reward for the referrer.
However, the latest adjustments are more substantial for both the buyer and the owner, offering pretty sizeable discounts on the purchase price of a Model S, Model X, or Cybertruck.
There are also discounts for current owners, giving them money off of all five Tesla vehicles.
Here’s the rundown of the new Referral Program awards:
- You’ll earn $250 in Tesla Credits for each person you refer who takes delivery of a new Tesla
- The first 10 people who order a new Model S, Model X, or Cybertruck using your referral link and take delivery will receive $1,000 off their purchase
- When you purchase a new Model S, Model X, or Cybertruck for yourself, you’ll get $1,000 off
- When you purchase a new Model 3 or Model Y, you’ll get $500 off
- Limited to 10 awards
Tesla changed the referral program slightly for those using your code! pic.twitter.com/JBFzKlxsJg
— David Lescatre Jr (@DavidLescatreJr) September 21, 2025
This is a pretty big discount as $1,000 off a Model S, Model X, or Cybertruck is a nice benefit to three of Tesla’s most expensive vehicles.
The additional $500 off a Model 3 or Model Y is also a nice cushion. A similar Referral Program was launched by Tesla last August.
News
Tesla adjusts ‘Actually Smart Summon’ to avoid one common complaint
Tesla is adjusting Summon Standby’s settings slightly to combat the loss of battery life some owners might see with the feature active.

Tesla has adjusted one portion of its “Actually Smart Summon” (ASS) feature to address a common complaint from owners: battery drain.
Teslas have a lot of really awesome features that make them one of the most technologically advanced vehicle models on the market. Things like Sentry Mode, Cabin Overheat Protection, and ASS’s “Summon Standby” features all keep the car on its toes for anything that comes its way.
Tesla finally launches Actually Smart Summon and Dumb Summon
However, the activation of these features contributes to battery drain while the vehicle sits parked. The amount varies, but I personally have lost up to five percent with some of these features active. That’s a lot if you do not utilize home charging.
Tesla is doing what it can to combat the battery drain with each of these features. It has done so with Sentry Mode, as an update last year helped combat battery percentage loss due to the activation of the security feature.
It also recently introduced “Low Power Mode,” which will automatically deactivate some features if your battery falls below 20 percent. This is a great way to combat battery loss if your car is parked somewhere long-term, like an airport, for example.
There is also another feature that is attached to ASS called “Summon Standby.” This keeps the vehicle awake in case the owner needs quick connectivity to the vehicle, allowing them to summon the car to their location swiftly.
But there’s a drawback: keeping this feature activated will drain the battery. By default, the feature is activated when you take your car home, so you have to turn it off manually by accessing the settings menu inside the vehicle.
Turning this off would save you between 2% and 3% overnight, in my experience. With ASS still being a feature that needs some work, I chose to turn Summon Standby off. ASS will still work with the standby mode deactivated; it will just take a few more seconds for your phone to connect to the vehicle.
Tesla is adjusting Summon Standby’s settings slightly to combat the loss of battery life some owners might see with the feature active.
According to Not a Tesla App, Tesla has rolled out two conditions for which Summon Standby will be deactivated automatically:
Overnight Deactivation
Summon Standby will automatically be deactivated from midnight to 6 a.m. every night, which appears to be a data-driven decision made by Tesla based on the feature’s least-used hours.
This automatic pause cannot be turned off, at least for the time being.
Extended Parking Deactivation
If your Tesla is parked for over 24 hours, Summon Standby will also be deactivated automatically.
This is a great way to save battery life for those who are on vacation or are at home for several days in a row. This works similarly to the Low-Power Mode we talked about earlier in this article.
Elon Musk
Neuralink is planning to launch US trials translating thoughts into text
The trial could help pave the way for people with speech impairments to communicate more quickly and efficiently.

Neuralink, Elon Musk’s brain-computer interface company, is reportedly planning to start a US clinical trial in October to use its technology to translate thoughts directly into text.
The trial was approved by the FDA under an investigational device exemption, and it could help pave the way for people with speech impairments to communicate more quickly and efficiently.
Thought-to-text technology
The upcoming trial aims to read speech directly from the brain, enabling participants to transmit words without moving their mouths or using a keyboard, as noted in a report from Bloomberg News.
DJ Seo, Neuralink’s president, told an audience at the Korea Foundation for Advanced Studies in Seoul that the company hopes to demonstrate communication with large language model AI platforms “at the speed of thought,” potentially faster than spoken speech.
“We think that it’s actually possible to demonstrate abilities to speak to the latest AI model, or LLM models, at the speed of thought, even faster than how you’re speaking, and being able to potentially get that information back through your AirPods, effectively closing the loop,” Seo stated.
Production ambitions
Ultimately, Seo described the trial as a stepping stone toward broader human enhancement and consumer-facing applications, beyond the company’s initial focus on medical conditions like ALS, stroke, blindness, and Parkinson’s disease.
While initial implants will focus on patients with severe speech impairments, Neuralink plans to eventually expand to healthy individuals by 2030. The company aims to scale to 20,000 implants per year by 2031.
“We’re currently envisioning a world where, in about 3 to 4 years, there will be someone who’s otherwise healthy who’s going to get a Neuralink. If you’re imagining saying something, we would be able to pick that up,” the executive noted.
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