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SpaceX’s Starship, Starhopper prototypes continue slow and steady progress

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The last few weeks of SpaceX’s work on Starship and Starhopper prototypes has been marked by less visible progress relative to the past few months. The changes that are visible, however, confirm that its Boca Chica engineers are working around the clock to complete the first orbital Starship prototype.

At the same time, it appears that SpaceX’s South Texas facilities are preparing for a rapid period of expansion and build-up. New work around the ad-hoc Starhopper pad has recently begun, while construction of a second concrete jig for concurrent prototype fabrication and what will likely be a more permanent hangar and control facility are also ramping up. Things have been quiet news-wise for SpaceX’s McGregor and Hawthorne facilities but there is reason to believe that Raptor production and testing is going smoothly.

Starship Alpha

The most obvious visible progress made in April is centers around SpaceX’s first orbital Starship prototype, soon to begin its third month of active construction. As of mid-March, the shells of two large steel barrel sections – together about 18 m (60 ft) tall – were fully erected at the build site, with a handful of other sections in various states of welding. The height of those two cylinders has remained unchanged since then but it’s safe to assume that a ton of work has been going on inside them, invisible to anyone viewing from public perspectives since drones were effectively banned in March. In other words, the two pieces – most likely the barrel sections of Starship’s liquid methane and liquid oxygen (LOX) tanks – are likely being carefully transformed into actual propellant tanks.

A look inside SpaceX’s 2017 version of a 9m-diameter Starship.

There is also a good reason for their height differential: the larger (LOX) section is almost exactly a third larger than the small section (methane) in part because of the physical reality that Starship will need almost exactly 33% more LOX than methane by volume. Large propellant tanks – particularly those meant for cryogenic fluids and spaceflight applications – are often quite complex, with the vast majority of that complexity happening under the hood. The above render was made while SpaceX was still planning on carbon fiber tanks and also appears to be significantly simplified, but it still offers a small look at some of that complexity.

Aside from successfully completing thousands of welds throughout the assembly, a lot of the effort of building an advanced tank is put into plumbing – both internal and external – needed to load, unload, pressurize, depressurize, and generally manage cryogenic (i.e. super cold) liquid propellant. SpaceX decided to utilize a partial balloon tank design to keep the steel skins of its stainless steel Starship and Super Heavy as thin as possible, adding yet another level of internal work due to the need for stringers and longerons on top of baffles and hardware to mount COPVs or header tanks.

Starship glows red and white-hot as it reenters Earth’s atmosphere. (SpaceX)
SpaceX already uses stringers (the grid-like structure) in Falcon 9’s RP-1 tank. (SpaceX)

Adding further complexity to the internal structure of Starship is the presence of major aerodynamic surfaces and landing legs, both of which will need to survive extreme stresses if they are to function as intended. Those structures must be aerodynamically streamlined and attach to the outside of Starship’s hull, likely requiring significant structural reinforcements both inside the spacecraft’s nose and rearmost propellant tank.

Super Heavy?

SpaceX began construction of a second concrete fabrication jig just a handful of days ago. Effectively a copy of a jig occupied with the larger of the two barrel sections of the orbital Starship prototype, the simple structure acts as a mount and includes a large door that allows scissor lifts to get inside the steel structure. The new jig is being built directly adjacent to Starship’s smaller barrel section, suggesting that it could simply be a way to concurrently work on both the LOX and methane tanks. Given the inherent simplicity of a concrete jig, it could also end up being used to support the simultaneous assembly and integration of the first Super Heavy booster prototype.

Back in December 2018, SpaceX CEO Elon Musk indicated that the first Super Heavy prototype would start production in “spring” (i.e. NET April 2019). Musk has also indicated that Starship and Super Heavy will be simultaneously built both in Boca Chica, Texas and Cape Canaveral, Florida. In general, SpaceX is clearly beginning another round of expansion and improvement for its Boca Chica facilities, including the new concrete jig and an entirely new building on the same plot of land.

SpaceX began filling the new jig with concrete on April 24th. (NASASpaceflight – bocachicagal)

Starhopper

Last but not least is SpaceX’s Starhopper prototype. After completing an inaugural round of multiple wet dress rehearsals (WDRs) and two Raptor static fires/hops, SpaceX technicians removed the vehicle’s lone Raptor engine on April 8th. Starhopper has remained more or less inactive in the last two weeks, aside from some work going on inside the vehicle (per the open access hatch).

Without a Raptor engine, there is admittedly not a whole lot that SpaceX can do with Starhopper, aside from additional WDRs if the first handful of tests were not enough. Instead, some minor work has been going on around the Hopper’s ad hoc pad, mainly taking the appearance of dirtmoving. Without aerial views, its hard to tell what exactly is taking shape, but it’s safe to say that Starhopper is simply waiting for additional Raptors to be produced, tested, and delivered to Boca Chica. Once more Raptors are ready, it’s understood that SpaceX will move into multi-engine (likely 3+) hop tests, perhaps loosing Starhopper from its tethers.

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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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Starlink launches Communities Program for passive income through internet sharing

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(Credit: Starlink | X)

Starlink is launching a new beta path for ordinary property owners and local operators to turn a single Starlink kit into a small shared-access business for passive income.

Under the Starlink for Communities program, a host installs one dish and router setup in a location with nearby demand: an apartment complex, campground, rural crossroads, or event site. Neighbors or local users can buy short-term passes rather than full individual subscriptions, giving the Starlink provider a potential path to passive income.

Hour, day, and week passes cover one device. A month pass covers up to four. Starlink handles account creation, payments, access controls, and the satellite link itself. The host’s role is mainly placement, power, and basic upkeep, with earnings tied to each paid connection.

The model echoes the passive-income vision long attached to Tesla’s Robotaxi plans, and it seems like it’s something Musk has hinted toward in the past as he believes AI will make the need to work relatively optional. In both cases, the platform owns the hard parts of matching, billing, and network management, while an individual supplies a physical asset that sits idle much of the time.

A Starlink host’s dish can serve multiple nearby users without each household buying and installing its own terminal. A Tesla owner, under the stated Robotaxi concept, would leave a vehicle enrolled in the fleet during unused hours so the car generates rides while the owner is at work or asleep.

Both arrangements convert under-utilized hardware into a revenue stream. They also let the company scale coverage or capacity without owning every endpoint.

Differences are practical. A Starlink kit is a fixed, relatively low-cost terminal whose main constraint is local congestion and line-of-sight. A Tesla Robotaxi is a mobile, high-value vehicle whose earnings depend on demand density, utilization rates, insurance, cleaning, and charging.

Starlink’s program is already accepting host applications in multiple countries and describes the revenue split as ongoing. Tesla’s owner-network version remains more aspirational.

The company currently operates a limited company-controlled robotaxi service in select areas and has solicited interest from fleet buyers for Cybercab vehicles, while private Full Self-Driving owners have not yet been able to dispatch their own cars for paid rides at scale.

Tesla primes Cybercabs for 4K streaming and high bandwidth gaming with Starlink integration

Starlink is a satellite broadband service operated by SpaceX that uses a constellation of low-Earth-orbit satellites to deliver internet to locations where terrestrial broadband is slow, expensive, or absent. It has grown to millions of subscribers worldwide by selling direct residential, mobile, and enterprise terminals, and have become widely available at a wide array at retail locations like Target and Best Buy.

The Communities program extends that reach by letting hosts resell short bursts of capacity to people nearby, while also providing high-speed internet access to those who are simply around a Starlink user.

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SpaceX’s midnight spy satellite launch quietly set a new record

Falcon Heavy launched its first NRO mission while SpaceX landed four boosters in one day.

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SpaceX's Falcon Heavy lifts off from Launch Complex 39A at NASA's Kennedy Space Center at 11:54 p.m. ET on October 1, 2026, carrying the classified NROL-97 mission for the National Reconnaissance Office. (Credit: SpaceX)
SpaceX's Falcon Heavy lifts off from Launch Complex 39A at NASA's Kennedy Space Center at 11:54 p.m. ET on October 1, 2026, carrying the classified NROL-97 mission for the National Reconnaissance Office. (Credit: SpaceX)

SpaceX closed out one of its busiest days ever with a midnight Falcon Heavy launch from Florida, and the rocket’s two side boosters came home to finish off a landing record the company had never set before.

Falcon Heavy lifted off from Launch Complex 39A at NASA’s Kennedy Space Center at 11:54 p.m. ET Thursday carrying NROL-97, a classified payload for the National Reconnaissance Office. It was the first time the NRO has flown on Falcon Heavy after 22 missions on Falcon 9, and the first NRO mission bought through the National Security Space Launch Phase 3 Lane 2 contract awarded in 2025, according to Spaceflight Now.

Roughly eight minutes after liftoff, side boosters B1104 and B1072 touched down at Landing Zones 1 and 2 at Cape Canaveral Space Force Station, setting off double sonic booms across Brevard County. B1104 was flying for the second time and B1072 for the fourth. Both last flew on August 30 on NASA’s Nancy Grace Roman Space Telescope, making NROL-97 the quickest turnaround between Falcon Heavy missions to date. The brand new center core, B1106, was expended in the Atlantic so the payload could reach its high energy orbit, and SpaceX’s mission page noted the fairing had previously flown on the NROL-95 mission in July.

The two landings capped a record for SpaceX. Earlier Thursday, Falcon 9 booster B1101 returned to Landing Zone 40 after sending the Crew-13 astronauts to the International Space Station, and another Falcon 9 launched the Transporter-18 rideshare with 130 payloads from Vandenberg Space Force Base in California. Spaceflight Now reported it was the first time SpaceX has landed four boosters in a single day, wrapping up the triple header Teslarati previewed on Wednesday.

The mission also brought Landing Zone 1 back for what may be its final landing. SpaceX first landed an orbital class booster there in December 2015, but its lease on the former Launch Complex 13 site ended in 2025 as the company moved Florida landings to new pads at its own launch complexes. With LZ-40 already holding the Crew-13 booster, SpaceX brought LZ-1 back into service for one more night. Launch tracker Next Spaceflight listed NROL-97 as the final expected landing at the site.

NROL-97 adds to a fast growing stack of national security work for SpaceX. The company has flown four Space Force missions from Vandenberg since mid August, several believed to carry Starshield satellites, pushing its Pentagon contract total for 2026 past $8 billion. Elon Musk was also named this week to help lead the Pentagon’s Project Meridian study on the future of warfare.

The Florida doubleheader stood out for another reason. The Space Coast saw only one launch in all of September as SpaceX shifts more of its East Coast infrastructure toward Starship, which reached orbit for the first time on Flight 14 just three days earlier.

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Elon Musk

SpaceX nails “Lucky 13” astronaut launch, leaning into Tesla tradition and superstition

SpaceX launched Crew-13 astronauts to the ISS Thursday, setting up a record fast Dragon docking.

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Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)

SpaceX launched NASA’s Crew-13 mission to the International Space Station on Thursday morning, getting four astronauts to orbit despite a forecast of thunderstorms and gusty winds that had threatened to push the flight to Friday.

Falcon 9 lifted off from Space Launch Complex 40 at Cape Canaveral Space Force Station at 11:10 a.m. ET carrying Dragon Grace, NASA confirmed. On board are NASA commander Jessica Watkins, NASA pilot Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov. The first stage booster, B1101, landed at Landing Zone 40 beside the pad on its third flight after previously supporting Crew-12 and a Starlink mission.

It was the first spaceflight for Delaney, Kutryk and Teteryatnikov. Watkins, who flew on Crew-4 in 2022, became the first NASA astronaut to launch aboard a Crew Dragon twice.

Before launch, the crew rode to the pad in Teslas, a tradition on NASA’s SpaceX crew flights since 2020. This time the cars carried specialty plates reading “Lucky 13.” Watkins said the mission patch leans into the number on purpose, as a nod to Apollo 13 and the resilience of that crew.

Grace is now on a short trip to the station. Docking at the forward port of the Harmony module is scheduled for about 7 p.m. ET, roughly 7 hours and 50 minutes after liftoff, which Space.com notes would be the fastest Crew Dragon transit to the ISS yet. Most Dragon flights take around 15 to 24 hours to catch the station. Hatch opening is planned for 8:25 p.m. ET.

The launch came more than two weeks later than originally planned. An oxidizer leak was found in Grace’s propulsion system in August, and NASA and SpaceX added time for tests. That pushed back the return of Crew-12, which has been aboard the station since February and is now set to splash down off Southern California next week. Crew-13 is expected to stay about six months.

SpaceX rescue mission for stranded ISS astronauts nears end — Here’s when they’ll return home

SpaceX already holds NASA orders for crew rotations through Crew-17, while Boeing is preparing an uncrewed Starliner flight to the station as early as December.

Crew-13 was only the first of three SpaceX launches planned for Thursday, as Teslarati previewed on Wednesday. A Falcon 9 launched its Transporter-18 mission from California today, where Google will be launching its first orbital artificial intelligence (AI) test satellite. Meanwhile, Falcon Heavy is set to launch the classified NROL-97 mission for the National Reconnaissance Office from Launch Complex 39A at 11:53 p.m. ET. Its two side boosters will return to Landing Zones 1 and 2, which means Central Florida could hear up to three sonic booms in a single day. The busy stretch follows Starship’s Flight 14 on Monday, which reached orbit for the first time.

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