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SpaceX’s thin-skinned Starship ‘test tank’ passes first trial

Elon Musk says that SpaceX's first 3mm-thick Starship test tank passed its first major trial. (LabPadre)

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CEO Elon Musk says that a new thin-skinned Starship ‘test tank’ just passed its first trial, taking advantage of delays to Starship SN9’s planned high-altitude launch debut.

Delayed by a lack of FAA approval for unknown reasons, Starship SN9’s 12.5-kilometer (7.8 mi) launch debut (virtually identical to SN8’s 12.5 km launch last month) is in limbo pending an “FAA review” according to Musk. SpaceX thus found itself with at least 24 hours of guaranteed inactivity for Starship SN9, time the company rapidly chose to fill with crane transportation and, more importantly, the first Starship ‘test tank’ stress test in months.

Known as Starship SN7.2, SpaceX’s latest ‘test tank’ is the third to carry the SN7 moniker and appears to have been built primarily to test refinements to the rocket’s structural design. Following test tanks SN7.0 and SN7.1, both used to qualify the use of a new steel alloy on an otherwise unchanged design, SN7.2 – likely built out of the same alloy – is instead focused on determining if SpaceX can begin trimming the margins of an increasingly mature technology.

Starship test tank SN7.0 and SN7.1. (NASASpaceflight – bocachicagal)
SN7.2. (NASASpaceflight – bocachicagal)

Curiously, SN7.2 is a sort of fusion of its predecessors: combining the stout stature of SN7.0 with SN7.1’s use of an aft thrust dome, but without SN7.1’s Starship-style skirt (the three rings at its bottom). Welded directly to its black test stand, it’s unclear why SpaceX chose to give SN7.2 a thrust dome, given that the thrust of Raptor engines can only be simulated with hydraulic rams if the tank is installed on one of two Starship launch mounts.

Regardless, whether SpaceX actually tests that aspect of SN7.2, the tank’s most important task is determining if future Starships (and perhaps Super Heavy boosters) can be built out of thinner, lighter steel rings. Its domes appear to be identical to past ships but writing on the exterior of the tank strongly implied that its three rings were built out of 3mm steel rather than the 4mm sheets that have made up every Starship built in the last 12 months.

SpaceX began loading the thin-skinned tank with liquid nitrogen (used to simulate cryogenic propellant without the risk of an explosion) around 9am CST and spent around three hours performing an “initial pressure test.” It’s unclear what that test entailed but it most likely involved raising the tank’s internal pressure to levels achieved by SN7.0 and SN7.1 Musk has previously said that that 6 bar was the bare minimum necessary for orbital flight, translating to 7.5-8.5 bar to achieve an industry-standard safety margin of 25-40%.

That SN7.2 survived that initial pressure test bodes well for the significant mass reductions SpaceX will need to optimize Starships for efficient orbital flight, potentially shaving 5-10 metric tons off the dry mass of future ships. For orbital rocket stages, every single kilogram of mass reduction translates to an extra kilogram of cargo capacity, whereas boost stages (i.e. Super Heavy) offer far more lenient ratios on the order to 10:1, meaning that adding 5-10 kilograms of rocket hardware reduces maximum payload capacity by just ~1 kg.

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Depending on when SpaceX is allowed to launch Starship SN9, the company’s next test could involve pressurizing SN7.2 until it bursts, determining if the tank’s thinner skin substantially impacts its performance as a pressure vessel.

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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SpaceX’s next Starship launch is about to attempt its biggest leap yet

SpaceX targets September 22 for Starship Flight 14, its first attempt to reach real orbit.

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SpaceX has set September 22 as the target date for Starship’s 14th test flight, and this one carries a different goal than any of the 13 that came before it. Every previous Starship mission has intentionally flown a suborbital arc, reentering the atmosphere within the same hour it launched. Flight 14 is designed to send the craft into a genuine orbit around Earth for the first time.

The launch window opens at 7:15 a.m. Central time at Starbase in South Texas and runs for 75 minutes, pending regulatory approval, according to SpaceX’s mission description published Tuesday. If the flight goes as planned, Starship will circle the planet roughly six times at an altitude near 275 kilometers over about ten hours before a deorbit burn sends it toward a splashdown in the Pacific Ocean west of Chile, a departure from the Indian Ocean recoveries used on the last several flights.

The mission also marks the first attempt to put a working batch of Starlink V3 satellites into actual service. Flight 13 carried 20 of the new satellites in July, but because that mission never left a suborbital trajectory, the payload reentered along with the ship instead of separating into orbit.

SpaceX tells the FCC that Starship Flight 14 is going to orbit

Each V3 satellite is rated for roughly one terabit per second of downlink capacity, so a successful deployment on Flight 14 would be SpaceX’s largest single jump in network bandwidth since Starlink began flying on Falcon 9.

Flight 13 still did the heavier lifting on the technical side. That July mission flew a deliberately more stressful reentry profile to test Starship’s heat shield, and the ship survived its softest splashdown yet, intact enough for drone inspections shortly after landing. Elon Musk said the flight delivered “all the heat shield data we needed and then some,” a result Teslarati covered in detail when he later said SpaceX had solved the vehicle’s biggest reusability challenge. Flight 14 is where SpaceX starts spending that confidence on an actual orbital insertion rather than another controlled fall back to Earth.

One thing Flight 14 will not attempt is a tower catch of the ship. Musk floated the idea right after Flight 13, but walked the timeline back in August, saying a catch attempt was more likely “in a few months.” The Super Heavy booster will still aim for its own recovery, targeting an offshore landing point in the Gulf of America, the same approach used on recent flights.

September 22 is SpaceX’s own target, not a locked date. Starship’s schedule has slipped before over hardware readiness and FAA sign off, and the company has said as much in its own mission notes. But the plan itself represents the clearest marker yet that Starship is moving from a suborbital test program into something meant to carry paying payloads and, eventually, people.

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Elon Musk gives his most telling Tesla-SpaceX merger conversation yet

Elon Musk hinted a Tesla-SpaceX merger could be coming, and Wall Street is taking notice.

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Elon Musk gave his clearest signal yet that Tesla and SpaceX could eventually combine, telling the All-In Summit in Los Angeles that the two companies’ deepening collaboration makes the question worth asking. Sawyer Merritt first surfaced the highlight on X Tuesday.

Asked directly why Tesla and SpaceX remain separate given how closely they already work together, Musk told hosts at the summit: “Great question there. With all this collaboration, on so many levels, who can imagine what action one might take when there’s so much close collaboration in so many areas.” SpaceX President Gwynne Shotwell, who joined Musk on stage, added that SpaceX personnel have already moved into xAI to fill leadership and engineering gaps, saying the businesses are integrating “faster than I thought,” though “not fully integrated yet,”

The comments landed on top of merger speculation that has been building on Wall Street for months. JPMorgan has called a tie-up “strategically coherent on paper,” pointing to overlapping ambitions in AI, robotics, energy, transportation and space. Jefferies went further, estimating Musk could retain roughly 55.3 percent voting control in a deal structured without a premium, a scenario that would still leave room for Tesla shareholders to come out ahead. On Kalshi, traders now put the odds of a merger before 2028 at 66 percent.

Tesla’s stake in SpaceX, still under one percent, traces back to its earlier investment in xAI, which converted to SpaceX equity after SpaceX absorbed the AI company. The two are also jointly building Terafab, a chip facility in Austin meant to serve both Tesla’s AI computing needs and SpaceX’s satellite ambitions. Wedbush analyst Dan Ives has stood by a 2027 merger timeline for months, and Cathie Wood’s ARK Invest recently floated a similar case, an idea Musk pushed back on directly at the time.

Another Tesla SpaceX merger prediction by ARK Invest has Elon Musk talking

The timing adds another layer. Tesla has scheduled an October 1 unveiling for its next generation Roadster at a venue near SpaceX’s McGregor, Texas test site, using the phrase “Go for launch” in its promotional material. Both stocks dipped roughly 2 percent Monday before recovering slightly in premarket trading Tuesday, with SpaceX shares up about 0.4 percent and Tesla essentially flat.

Musk stopped short of confirming anything is in motion. But unlike his past denials of a corporate restructuring, this response didn’t rule one out, and it came with Shotwell sitting next to him describing an integration that’s already underway.

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Tesla Roadster unveiling is getting hyped up by Elon Musk

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tesla roadster
Credit: Petersen Auto Museum

The Tesla Roadster unveiling is getting hyped up by the company’s CEO Elon Musk, who has been a big reason the product has such high expectations due to delayed timelines and a constant need to make it even more insane than before.

Tesla announced on September 12 that it would officially unveil the Roadster in Waco, Texas, on October 1, ending years of patience for fans and reservation holders who have waited for the all-electric supercar to enter production since 2017.

Musk has said that this event will be well worth the wait on several occasions, and last year on the Joe Rogan Experience, he said that there should be a closing chapter to supercars- the end of cars that aren’t focused on safety.

He said:

“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one. I think it has a shot at being the most memorable product unveil ever. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”

Musk’s teases have continued, and now that the event is roughly two weeks away, it seems like Roadster is finally going to show up and blow some minds:

Tesla has definitely dragged out the development of the Roadster, but there is a good reason for it.

Tesla has been working on many other projects, most notably self-driving efforts to increase passenger safety, and those simply took priority over the Roadster, a low-volume, high-performance sports car that has a lightning-fast acceleration rate of 0-60 MPH in just 1.1 seconds, could potentially fly, and contributes very little to the company’s mission.

However, many people have the Roadster on pre-order through the referral program or with their own money, and it is time that Tesla delivers on that.

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