News
SpaceX preps Starship, Super Heavy for another week of Raptor testing
SpaceX continues to work around the clock to prepare its latest Starship and Super Heavy booster prototypes for another week of testing – likely focused on firing up the Raptor engines installed on each vehicle.
Known as Booster 7 and Ship 24, SpaceX has been slowly testing both prototypes for approximately four months, beginning in April and May, respectively. Only in early August did the company cautiously begin attempting to ignite their Raptor engines as part of a process known as static fire testing – by far the most difficult and important part of qualifying both vehicles for flight.
Thanks to progress made in 2021, SpaceX already has significant experience testing an earlier orbital-class Starship prototype on the ground, but the process of testing Ship 24 is still fresh and unfamiliar for a number of reasons. For Booster 7, the challenges are even greater.
On top of major design changes made to Starship and Super Heavy over the last year as SpaceX continues to refine the rocket, the company also developed a substantially different version of its Raptor engine. Compared to Raptor V1, Raptor V2 almost looks like a new engine and can produce around 25% more thrust (230 tons versus 185 tons). SpaceX has also tweaked how the engine operates, particularly around startup and shutdown, further weakening the value of past experience testing Raptor V1 and V1.5 engines on Ship 20 and Boosters 3 and 4.
In other words, with Ship 24 and Booster 7 engine testing, it’s possible that SpaceX is effectively starting from scratch. Many aspects of testing – propellant conditioning, thermal characteristics, tanking, detanking, certain test stands – are likely mostly unchanged, but almost every aspect of a rocket is affected by its engines.
Before SpaceX began testing Raptor V2 engines on Starship and booster prototypes, it wasn’t clear if the changes between V1.5 and V2 would invalidate a lot of prior testing. After the start of Booster 7 and Ship 24 static fire testing, it’s now clear that a lot of that earlier work has to be redone. It’s also clear that despite some of the simplifications in Raptor V2’s design, operating the engine on Starship and Super Heavy is much harder get get right.
Since mid-July, SpaceX has completed around 15-20 ‘spin-prime’ tests between Ship 24 and Booster 7 – more of that kind of test than any other prototype in the history of Starbase has performed. Spin-prime tests flow high-pressure gas through Raptor’s pumps to spin them up without igniting anything. It’s unclear why so many of those tests are being done, what SpaceX is gaining from it, or why the company appears to have completely stopped conducting preburner tests (a more life-like spin-prime with partial combustion).
Regardless, eight weeks after the start of engine testing, Booster 7 has only performed three static fires (two with one engine, one with a max of three or four engines), and Ship 24 has only completed one static fire with two engines. Before either vehicle can be considered ready for flight, a day that could easily never come, each will likely need to conduct multiple successful static fires with all of their Raptor engines (6 on S24 and 33 on B7).
If the pace of Booster 7 testing doesn’t change, the vehicle could be months away from a full 33-engine static fire attempt – perhaps the single most important and uncertain test standing between SpaceX and Starship’s first orbital launch attempt. Ship 24’s path to flight readiness should be simpler, but it appears to be struggling almost as much.
According to CEO Elon Musk, “an intense effort is underway” to ensure that Super Heavy B7’s Raptor engines are well contained during anomalies, so that one engine violently failing won’t damage or destroy the booster, other engines, or the launch pad. That could certainly complicate the process of testing Booster 7, and it’s likely that SpaceX is taking some of the same actions to protect Ship 24.
In early September, after a partially successful Booster 7 static fire (its first multi-engine test) and numerous additional Ship 24 tests that failed to achieve ignition, SpaceX replaced engines on both vehicles. Booster 7 had one of 13 Raptor Center engines swapped out, while Ship 24 had one of its three Raptor Vacuum engines replaced.
On September 5th, SpaceX distributed a safety alert to Boca Chica’s few remaining residents, confirming that it wants to restart testing as early as Tuesday, September 6th. Especially as of late, that alert guarantees nothing, but it does at least open the door for SpaceX if Ship 24, Booster 7, and the positions of the stars happen to be in the right mood between 8am and 8pm CDT. Additional opportunities are available on September 7th, 8th, 9th, and 12th.
News
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.
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.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
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.
Investor's Corner
New drone video shows Tesla’s Optimus Factory reaching a turning point
New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.
Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.
Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.
Tesla Giga Texas to feature massive Optimus V4 production line
The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.
Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.
Investor's Corner
Tesla and SpaceX take “Terafab” Trademark fight to Federal Court
Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.
Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.
The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.
What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.
TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.
Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.
The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
New drone video shows Tesla’s Optimus Factory reaching a turning point
