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SpaceX’s upgraded Super Heavy booster sails through first major test

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SpaceX’s first upgraded 33-engine Super Heavy booster appears to have passed a crucial test with surprising ease, boding well for a smooth qualification process.

Attempting that test so early on did not appear to be SpaceX’s initial plan. Instead, shortly before Super Heavy Booster 4’s third and likely final removal from Starbase’s ‘orbital launch mount’ (OLM) on March 24th, SpaceX transported a massive structural test stand from a Starbase storage yard to the orbital launch site (OLS), where technicians have focused on modifying nearby ground systems to support apparent structural testing of Super Heavy Booster 7. As of March 31st, all available evidence suggested that SpaceX was preparing that stand to verify Booster 7’s mechanical strength and simulate the major stresses it might experience before investing a significant amount of time and resources in qualification testing.

However, SpaceX appeared to change its plans at the last minute.

Instead of starting with structural testing, after a brief two-day pause, SpaceX rolled Super Heavy B7 into place and craned the giant booster onto the orbital launch mount on April 2nd. On April 3rd, the launch mount’s “quick disconnect” device connected Super Heavy to the pad’s ground systems. On April 4th, just two days after its installation on the OLM, Super Heavy B7 kicked off the first in a series of qualification tests that will determine when or if the booster ultimately supports Starship’s first orbital launch attempt.

If testing goes perfectly, SpaceX CEO Elon Musk recently stated that Starship and Super Heavy – likely Ship 24 and Booster 7 – could be ready for an inaugural orbital launch attempt as early as May 2022. SpaceX appears to have leaped headfirst into Super Heavy Booster 7 qualification testing in a move that significantly increases the likelihood of meeting that extremely ambitious schedule. Normally, with a first-of-its-kind prototype debuting multiple significant design changes, SpaceX would start slow, possibly beginning with a basic pneumatic proof test to verify structural integrity at flight pressures – about 6.5-8.5 bar (95-125 psi) – with benign nitrogen gas before calling it a day.

With Booster 7, SpaceX likely still performed a quick pneumatic proof but then immediately proceeded into a full-scale cryogenic proof test. With Super Heavy B4, for example, SpaceX performed several increasingly ambitious cryogenic proof tests, filling the booster more and more each attempt but never actually topping it off. On Booster 7’s very first day of testing and first cryogenic proof attempt, SpaceX fully loaded the upgraded Super Heavy with a cryogenic fluid (likely liquid nitrogen) in just two hours – all with no significant unplanned holds (pauses).

In those two hours, SpaceX likely loaded Super Heavy B7’s liquid methane (LCH4) and oxygen (LOx) tanks with roughly 3400 metric tons (~7.5M lb) of liquid nitrogen (LN2) – not far off what Super Heavy would actually weigh at liftoff. At the peak of the test, Booster 7 was almost entirely covered in a thin layer of ice produced as the cryogenic liquid inside its tanks froze water vapor in the humid South Texas air onto its skin – an effect that effectively turns uninsulated cryogenic rockets into giant fill gauges. On top of running into no apparent issues, Super Heavy B7’s first cryogenic proof is also the first time any Super Heavy prototype has been fully filled during testing – an important milestone for any rocket prototype, let alone the largest rocket booster ever built.

Completing a full cryogenic proof test on its first try makes Booster 7 fairly unique among all Starship prototypes – not just Super Heavies. The contrast with Booster 4, which barely completed a handful of partial cryogenic proof tests in more than half a year spent at Starbase’s orbital launch site, is also extremely encouraging, suggesting that Booster 7 won’t be sitting inactive for months at a time.

Still, cryogenic proofing is just one of several important tests Booster 7 needs to complete. Even if the first test was nearly perfect and SpaceX doesn’t attempt one or several more cryoproofs with higher tank pressures or other tweaked variables, Super Heavy B7 needs to complete wet dress rehearsal testing (WDR) with flammable LCH4/LOx propellant and demonstrate autogenous pressurization (using heated propellant gas to pressure its tanks). At some point, SpaceX will also need to install a full 33 Raptor V2 engines on the booster and seal off the whole engine section and each Raptor with a heat shield.

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Booster 4’s 29 partially shielded Raptor engines. (Starship Gazer)
B4’s fully shielded engine section. (NASASpaceflight)
At the moment, B7 has no Raptors and no shielding installed. (NASASpaceflight – bocachicagal)

Depending on how many Raptor V2 engines are available, SpaceX could begin static fire testing with just a few engines installed and shielded and then install the rest of the engines and heat shield later on. On the other hand, performing static fires without a full heat shield could risk damaging unprotected cabling or other subsystems, in which case wet dress rehearsal testing would likely follow immediately after cryoproofing and before engine or shield installation. After being skipped over, the structural test stand may also factor into Booster 7 qualification sometime before engine installation.

All told, plenty of uncertainty remains, but Super Heavy B7’s auspicious start suggests that the Booster 4 experience is far from a template and that SpaceX is much less interested in wasting time this time around.

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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Tesla Full Self-Driving v14.3.6 review: a rare regression, but some bright spots

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Credit: Tesla

Tesla released Full Self-Driving version 14.3.6 last week, and after what was potentially one of the best FSD releases in v14.3.5, there has been a bit of a regression. While there are some bright spots, the changes made to v14.3.6 seem to have backtracked some behaviors.

Overall, it is hard to really complain about FSD in any sense; it has revolutionized how I travel literally anywhere. According to my self-driving app, the last time I went a day without using it was 59 days ago.

However, I think it’s also important to recognize when things are just plain bad with FSD. There are times it does truly mind-boggling things, and I’ll dive into those here. Additionally, I only had these issues on local roads, not on highways. Highway operation, generally, is always incredible other than the occasional complaint about speed or left lane camping.

With those things being said, my personal experience may not represent others’ experiences. A handful of people have said they have had a similar experience on v14.3.6, while others have said it is more than normal.

Turning Hesitancy, Inaccuracy

I’ve noticed more inaccuracy turning into multi-lane stretches of road than in any version I can remember. I’ve had at least three instances of FSD turning into a stretch of roadway that has two or more lanes, and not selecting a lane confidently as it has in past versions.

Instead, the car will drive over one of the dashed road lines, and the steering wheel will jerk back and forth before picking the lane. It should be said that it has always picked the correct lane when choosing based on the navigation, but it is still very indecisive. The steering wheel jerking is reminiscent of some of the later versions of v13.

I admit I really hate to see the steering wheel jerking come back. However, I think when Tesla releases v14.3.7, it won’t be present. When there are occurrences of it in FSD versions, it is usually resolved by the following release.

FSD Disregards Manual Turn Signals

This is my biggest bone to pick with FSD other than Navigation issues, but this one seems like it would be such an easy fix.

If Tesla is going to put the word “Supervised” on the end of “Full Self-Driving,” then when I tell the car to do something, it should do it. If I input an increase in speed by pressing the accelerator, the car will immediately respond. It does not disregard my input because it feels it is traveling at the right speed.

FSD should never disobey and turn off turn signals that the driver inputs. Trying to direct the car into the correct lane, I had initiated the left turn signal not once, not twice, but three times, with the car turning it off all three times and continuing in a lane that would end in just one block. The only solution at this point would be to zipper merge.

This goes back to the fact that self-driving’s biggest bottleneck might be rider preference. A zipper merge might have been more than reasonable, might have saved me time that I spent sitting through an additional light cycle, and might be something many drivers would do. I was in no hurry, I traditionally do not try to zipper merge because it feels inconsiderate, and lastly, the car should have just followed my input.

This caused me to disengage and drive manually the rest of the way home. Sometimes I just do not need FSD to try to pass every car it can at intersections.

Bird Braking is a Thing of the Past

The big complaint with recent versions of Full Self-Driving has been what we’ve coined as “bird braking,” which is when the car will brake suddenly as a bird flies past.

There have been zero issues with this so far in v14.3.6, which is an excellent improvement.

FSD Might Already Be Taking Note of Driver Preferences

Another thing I have noticed over the past few days is that v14.3.6 seems to already be taking my preferences with navigation into account.

This is something that is supposed to be rolling out with the Summer Update, but I have a hunch it’s already present and might have been included in this v14.3.6 build. On Friday, FSD pulled into an entrance to a local convenience store that it had never attempted to go into before.

Typically, I manually pull into this entrance because it avoids heavy cross traffic at the main entrance. FSD has always chosen that congested main entrance.

Additionally, FSD has pulled into my assigned parking spot at my townhouse community on multiple occasions with this release. This is something that used to happen ocassionally, but not consistently.

It also navigated back to the same convenience store last night, drove through crazy cars scrambling to gas pumps, navigated out of the parking lot correctly, drove me home, and, once again, parked in my assigned spot.

As previously stated, this release just seems to have a few things that need to be brought to Tesla’s attention, and also to make others who use FSD aware of some things that I’ve experienced. I look forward to the next release that will remedy these issues, just as Tesla has always done in the past.

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Musk’s massive Terafab project will get final location soon

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Credit: SpaceX

Elon Musk’s massive Terafab project, which will be the first true conglomeration between each of his major entities, is set to get its final location soon, the CEO said on Tesla’s recent earnings call.

“The Terafab, we expect to announce a location soon, and provide more details about our plans in that regard. We’ll leave that to the product, the launch announcement rather than try to squeeze it into an earnings call,” Musk said last Wednesday.

Tesla Terafab set for launch: Inside the $20B AI chip factory that will reshape the auto industry

Terafab was announced by Musk back in March and was essentially a massive, vertically integrated semiconductor manufacturing project that would provide all the chips the three companies needed for their AI initiatives without needing third-party companies.

The plant will produce over 1 terawatt of AI compute each year, and will help back up projects like Optimus, Full Self-Driving, and other AI-based projects that Musk’s companies are working on.

In April, less than a month after the project was launched, Intel announced it would join the project, contributing manufacturing expertise and consulting to Terafab as a whole. Intel is one of three chip manufacturers that produce sub-5 nanometer chips at scale. TSMC and Samsung are the other two.

However, there was no true indication of where Terafab would end up, but most believe it will likely be somewhere in Texas. Business Insider has reported that SpaceX plans to build out Terafab in Grimes County, Texas, but this is unconfirmed.

Musk confirmed recently that it would not be on Giga Texas property, as it is simply too large.

Terafab holds much of Musk’s grand ambitions for the future within its construct. It holds so much responsibility for the future and the biggest projects that Musk’s companies can imagine.

“I think this is a very big announcement and it deserves to have its own day in the spotlight and not be squeezed into an earnings call,” he said. “I do think Terafab is going to be an amazing initiative and a necessary one, and one without which we will be constrained in our ability to scale Optimus production, because we simply won’t have enough AI chips.”

He continued by stating that Terafab is necessary for scaling Optimus, which Musk said could be the biggest product of any kind of all time. “It’s crucial to solve that, and we’ll have to solve memory, logic, and packaging in order to scale Optimus.”

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Elon Musk reveals SpaceX performed secret Starship test on Flight 13

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Credit: SpaceX

SpaceX performed a secret test on a specific portion of Starship with its recent 13th test flight last week, CEO Elon Musk revealed.

Starship’s 13th test flight took place last Friday, and in many aspects, it was one of the most overwhelmingly successful launches in the project’s history.

All of the mission objectives were met without incident, both the Super Heavy Booster and Ship managed to perform safe splashdowns in the Gulf of America and the Indian Ocean, respectively, and the deployment of Starlink satellites came and went without any complications.

However, there was more on the agenda for SpaceX with Flight 13. Musk revealed an internal test of the ship’s heat shield tiles, as the space exploration company wanted to push them to the limits after previous issues.

Many noticed that Starship’s initial launch seemed to be more accelerated than normal, and that was not a mistake. Musk revealed that SpaceX decided to give Flight 13 an intentionally aggressive acceleration rate in an effort to test how well the tiles would remain attached to the ship:

SpaceX had issues with some of the heat shield tiles remaining attached early on in the Starship program. The first six test flights presented some kind of anomaly with them, so the company’s big focus with them was to figure out a way to keep them intact through the duration of the flight.

Things truly improved as Flight 10 showed that ceramic tiles generally stayed attached to the ship far better due to refined attachment, as SpaceX utilized pins instead of adhesives. Flights 10 through 13 truly showed some clear progress with the heat shield tiles, and this latest test seems to be where some real progress was noticed, especially by Musk.

The 13th Starship launch last Friday was the second with Starship V3, SpaceX’s latest and greatest iteration of the spacecraft. Goals and ambitions are getting even grander as the project continues to progress. Musk has already hinted that SpaceX will likely try to catch Starship with Flight 14.

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