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SpaceX Starship prototype kicks off gauntlet of tests for the fifth time

SpaceX's fifth full-scale Starship prototype has kicked off a gauntlet of tests just hours after a Falcon 9 launch. (NASASpaceflight - bocachicagal)

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Hours after a successful Falcon 9 launch, a SpaceX Starship prototype has kicked off a challenging gauntlet of tests for the fifth time in hopes of becoming the first to take flight.

Five days after the ~30m (~100 ft) tall steel rocket was transported from the factory to the launch pad, SpaceX has fully integrated it with a brand new launch mount – built from scratch after operator error caused Starship SN4 to explode and destroy the prior mount. Assembled and outfitted with great haste, the new mount was completed just a day or two before Starship SN5 was moved to the pad and installed on top of it.

Triggered by a quick disconnect umbilical panel fuel leak that effectively caused a bomb-like fuel-air explosion, Starship SN4’s May 29th demise occurred shortly after a Raptor static fire test that was likely one of the last hurdles standing between SpaceX and the first full-scale Starship flight test. That fated static fire itself occurred a single day after SpaceX crossed a major regulatory milestone with an official FAA launch license for an effectively unlimited number of suborbital Starship flights. Now transformed into a pile of scorched scrap metal, Starship SN4 has passed the torch to Starship SN5.

Effectively identical to the gauntlet of tests Starship SN4 completed in the weeks prior to its destruction, Starship SN5 has kicked off its own test campaign with an ambient pressure test – a low-risk method of checking a pressure vessel for leaks. Starship SN5 apparently passed that first test without issue and SpaceX is now in the midst of loading the rocket tank section with cryogenic liquid nitrogen as a chemically neutral and nonexplosive stand-in for live liquid oxygen and methane propellant. (SN4 serves as a perfect illustration of why initial cryo proof tests are performed with LN2 instead of real propellant.)

SN4 was actually the first full-scale Starship prototype to survive a full cryogenic proof test, achieving 7.5 bar (~110 psi), so SN5’s success is far from guaranteed. Still, given SpaceX’s iterative, clockwork-like approach to development means that it’s far more likely than not that Starship SN5 will pass all the tests that its predecessor did – and then some.

SpaceX’s fifth full-scale Starship prototype has kicked off a gauntlet of tests just hours after a Falcon 9 launch. (NASASpaceflight – bocachicagal)

If Starship SN5’s cryo proof is successful, SpaceX has a few options available. Depending on the level of confidence in SN5, SpaceX could proceed directly into installing a single Raptor engine on the rocket’s triple-engine thrust structure and move on to wet dress rehearsals (WDRs) with methane and oxygen propellant. If a more cautious approach is preferred, SpaceX could perform a WDR or two before installing a Raptor engine. Either way, once the WDR phase is complete, Starship SN5 can begin live Raptor engine testing, starting with turbopump prime and preburner tests and culminating in one or several static fires.

Finally, once preburner and static fires have been completed without issue, SpaceX can begin to seriously prepare SN5 for its inaugural hop test, likely targeting an altitude of ~150m (~500 ft) before landing a few hundred feet from the launch mount. For now, many steps remain in the interim before Starship SN5 is even close to a hop test, but it shouldn’t take long to find out how long we’ll have to wait.

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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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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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Tesla’s secretive “Project Crystal Sun” gets a big green light in Texas

Fort Bend County approved four incentive agreements Thursday for Tesla’s proposed $10.1 billion solar factory.

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Elon Musk stands in profile against a clear blue sky, with a bright overhead sun shining above a vast landscape of Tesla solar panels stretching to the horizon, and a smaller Texas flag flying on a pole to his right.

Fort Bend County commissioners on Thursday approved a package of tax incentives for Tesla’s proposed $10.1 billion solar cell factory near Needville, Texas, giving the company one of the last local approvals it needs before it decides where to build. All four Tesla agreements passed 4 to 0.

The votes covered a property tax abatement inside Reinvestment Zone No. 34, a Chapter 381 economic development agreement, a foreign trade zone non-objection paired with payments in lieu of certain taxes, and a separate payment in lieu of taxes “true up” agreement, according to agenda notes from the Fort Bend Commissioners Court meeting.

The project, known internally as “Project Crystal Sun,” would make solar cells and finished modules on roughly 3,000 acres near FM 762 and FM 1994, south of the Brazos River. As Teslarati reported when the filing first surfaced in August, Tesla’s application under the state’s JETI Act splits the investment into $1.5 billion in real property and $8.6 billion in equipment, with 9,712 permanent jobs projected by 2033 and commercial operations targeted for the first quarter of 2029. The plant would handle the full chain from ingot and wafer production through cell testing.

Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing

Thursday’s approval does not lock in the site. Tesla has told the Texas Comptroller it is still weighing other locations, and site selection adviser David Dennison told Lamar Consolidated ISD trustees in September that the race had narrowed to Fort Bend and one out of state rival with a “very compelling package,” according to the Houston Chronicle. Tesla hopes to decide before the end of 2026, and the incentives still need sign off from the Comptroller and the Governor’s office.

Local officials have now done nearly everything within their control. Commissioners created the reinvestment zone in an August 24 special meeting, with Interim County Judge Daniel Wong formally withdrawing himself over his engineering firm’s past work with Tesla. Lamar CISD trustees voted 7 to 0 on September 15 to advance a JETI agreement that would tax Tesla’s qualifying property at 50 percent of its value for maintenance and operations from 2029 through 2038.

The plant lines up with a target Elon Musk set on Tesla’s Q4 2025 earnings call in January, when he said the company would “work toward getting 100 GW a year of solar cell production, integrating across the entire supply chain from raw materials all the way to finished solar panels.” In March, Tesla was reported to be negotiating a $2.9 billion purchase of Chinese solar manufacturing equipment bound for Texas. The Houston area already hosts Tesla’s Megafactory in Brookshire, where Megapack 3 production has started. Tesla said on its Q3 call that Megapack supply for 2027 is nearly sold out, and Musk wrote on X Thursday that the company is “increasing production of Megapacks as much as possible,” as demand from data centers climbs.

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Tesla is building its own maps to fix Navigation issues

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Credit: Tesla

Tesla revealed plans to develop its own maps internally to fix Navigation issues and give owners more control over their routing.

On the company’s Q3 2026 Earnings Call, a question was asked about FSD Navigation issues, particularly speed limit recognition, parking, and routing. These are issues that surface from version to version and seem to be seriously challenging for Tesla’s AI team to resolve.

Tesla’s Head of AI, Ashok Elluswamy, said in response to the question:

“You’re totally right that we shouldn’t be depending on external people’s maps. So we are building our own maps, but not like the same way as OneMoreMap. We are building an entirely new architecture with essentially AI-based mapping and navigation.”

He continued:

“It’s going to be super awesome. It’s going to be integrated with voice. You can talk to it, ask for different routes. It’s going to learn your personalized preferences, plus the fleet preferences. The collective intelligence of all the cars is going to flow into making the maps and navigation super cool.”

Elluswamy said this issue should be confronted, and the mapping should be available for people by the time the v15 release starts deploying to customers.

“And over the next several months,” he added, “it’s just going to take over all of the navigation functions, parking, destination handling. And it will know you better than you know yourself in some regard for the driving task, and then handle it fully.”

Tesla Summon got insanely good in FSD v14.3.2 — Navigation? Not so much

Navigation is perhaps the most notable complaint with FSD, and although it has gotten better, it is still flawed. Much of the time, FSD will take people on routes that are not preferred by the driver, but Tesla tried to combat this with a routing feature in the Summer 2026 Update.

Tesla currently relies on Google for map data, but it is sort of counterintuitive to believe the company would rely on a third party for this. These improvements will be welcome, as routing and navigation have been such a pain point for so many owners for so long.

Quotes via Motley Fool

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