Connect with us

SpaceX

SpaceX fully installs Super Heavy booster’s ‘aerocovers’

Published

4 years ago

on

For the first time, SpaceX has more or less installed a full set of ‘aerocovers’ on a Super Heavy booster prototype.

Designed to protect the booster from both itself and Earth’s atmosphere during ground testing, liftoff, ascent, and reentry, Super Heavy’s the structures amount to thin, steel shells mounted on metal box frames. The most obvious aerocovers slot over the top of six racks of equipment installed on the outside of Super Heavy’s aft end, giving the booster a sort of utility belt of hydraulic systems, pressure vessels, avionics, and heat exchangers. Unsurprisingly, those racks are festooned with electronics, composites, and thousands of feet of wiring and thin plumbing – none of which are particularly suited to sit a few dozen feet from the fury of 29-33 Raptor engines or near the leading edge of a hypersonic reentry vehicle.

Aside from the steel they’re mounted on, it’s likely that every system located on Super Heavy’s ‘utility built’ would begin malfunctioning or be destroyed outright if directly exposed to just a few seconds of the hypersonic buffeting and heating Starship boosters will experience during reentry. Unlike Falcon boosters, which almost always use reentry burns to slow down and create a sort of heat shield with their own exhaust, SpaceX is theoretically designing Super Heavy to survive the full force of reentry without an extra burn to cushion the blow.

To survive reentry and still land in good enough condition to enable anything close to same-day reusability, which is SpaceX’s goal, every ounce of at-risk equipment installed on Super Heavy’s exterior will likely need to be carefully shielded. In theory, that’s the purpose of the aerocovers SpaceX has only just begun to fully install – let alone test – on Super Heavy B4.

December 11th, 2021.
January 14th, 2022.

Before Booster 4’s most recent installation on the orbital launch mount, SpaceX did install covers over a pair of hydraulic and heat exchanger racks but left all four composite overwrapped pressure vessel (COPV) racks and an umbilical port uncovered. After B4 was removed from the launch mount for the third time on December 30th, both covers were uninstalled. On January 14th, 2022, though, SpaceX rapidly installed all six covers for the first time and began sealing each cover’s exposed corners. On January 17th, SpaceX even installed aerodynamic surfaces around Booster 4’s protruding umbilical port, smoothing out any hypothetical airflow around the device.

Prior to main aerocover installation, SpaceX also added at least half a dozen small boxes seemingly designed to protect a number of thin metal probes that pierce through Super Heavy’s tanks and skin and are connected to avionics boxes. Additionally, while less visible, teams also worked to finish Super Heavy B4’s Raptor heat shielding with a large number of similar sheet steel covers and panels. Without official photos from SpaceX or another lift onto the launch mount, it’s impossible to know if Booster 4’s Raptor heat shield is fully closed out, but the shielding that runs around its circumference appears to be finished.

Advertisement
Super Heavy B4’s Raptor heat shielding is partially visible in these views. (SpaceX)

As it stands, Super Heavy B4 is likely just a few parts shy of true completion and is about as ready as it’ll ever be for static fire testing. More likely than not, those aerocovers and Raptor heat shields are essential for Super Heavy B4 to be able to perform more than one test at a time without immediately requiring major repairs. Unlike Starship, which has mostly tested three engines at once and only performed a few six-engine static fires, Super Heavy B4 may eventually test all 29 Raptor engines simultaneously.

When almost 30 engines are involved, even nominal preburner testing will likely produce a massive fireball that could engulf Super Heavy’s aft (if not the entire booster) with flames. For static fire testing, Raptors typically produce a smaller and briefer (but still substantial) fireball during shutdown, creating another potential source of damage to any sensitive hardware located anywhere on or in Booster 4’s thrust section. As such, Super Heavy aerocovers may be just as important for surviving static fires as they’ll be for surviving launches and landings.

It’s unclear if or when Super Heavy B4 will return to the orbital launch mount for wet dress rehearsal and static fire testing. SpaceX has ambiguous test windows scheduled from 10am to 10pm on January 18th, 19th, and 20th.

Related Topics:

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.

Advertisement
Comments

News

SpaceX is rolling out a new feature to Starlink that could be a lifesaver

Starlink now has a new Standby Mode that will enable low-speed internet access in the event of an outage.

Published

6 minutes ago

on

August 13, 2025

By

(Credit: Starlink | X)

SpaceX is rolling out a new feature to Starlink that could be a lifesaver in some instances, but more of a luxury for others.

Starlink is the satellite internet service that Elon Musk’s company SpaceX launched several years ago. It has been adopted by many people at their homes, many airlines on their planes, and many maritime companies on their ships.

SpaceX produces its 10 millionth Starlink kit

It has been a great way for customers to relieve themselves of the contracts and hidden fees of traditional internet service providers.

Now, Starlink is rolling out a new service feature on its units called “Standby Mode,” which is part of Pause Mode. The company notified customers of the change in an email:

“We’re reaching out to you to let you know the Pause feature on your plan has been updated. Pause now includes Standby Mode, which comes with unlimited low-speed data for $5.00 per month, perfect for backup connectivity and emergency use. These updates will take effect in 30 days. All of your other plan features remain the same. You are able to cancel your service at any time for no charge.”

SpaceX did not define how fast these “low speeds” will be. However, there are people who have tested the Standby Mode, and they reported speeds of about 500 kilobytes per second.

The mode is ideal for people who might deal with internet or power outages, but still need to have some sort of internet access.

It could also be used as a backup for people who want to stay with their ISP, but would like to have some sort of alternative in case of an outage for any reason.

Continue Reading

News

SpaceX starts offering Starship services for Mars, and it already has its first customer

SpaceX has started offering Starship services to Mars, and it has its first customer already.

Published

6 days ago

on

August 7, 2025

By

Credit: SpaceX/X

SpaceX is yet to master its Starship spacecraft, but the company is already planning several steps ahead. As per recent updates from company leadership, SpaceX has started offering Starship services to Mars, and it has its first customer already.

Starship Updates

SpaceX President and COO Gwynne Shotwell recently posted an update about SpaceX’s Starship program on social media platform X. As per the executive, the private space company is now “offering Startup services to the red planet.” Shotwell also noted that SpaceX is working with the Italian Space Agency on an agreement.

Italian Space Agency President Teodoro Valente shared his excitement for the project in a post on X. As per Valente, the payloads in the mission would be gathering scientific data from Mars. 

“Italy is going to Mars! @ASI_Spazio and @SpaceX have signed a first-of-its-kind agreement to carry Italian experiments on the first Starship flights to Mars with customers. The payloads will gather scientific data during the missions. Italy continues to lead in space exploration!” Valente wrote in his post.

Next Starship Flight

SpaceX is currently making preparations for the launch of Starship Flight 10, which is expected to be held sometime this August, as per previous comments from CEO Elon Musk. At the end of July, SpaceX fired up its Starship Upper Stage on its South Texas launch site. This ship is the second that SpaceX has earmarked for Flight 10, as noted in a Space.com report, since the first exploded on a test stand on June 18 just before a planned static fire test.

Advertisement

A fully-stacked Starship first took to the skies in April 2023. Unfortunately, the last three missions this year, which were launched in January, March, and May, all ended with the upper stage experiencing a Rapid Unscheduled Disassembly (RUD) before its planned splashdown in the Indian Ocean. 

Continue Reading

Elon Musk

Elon Musk reveals SpaceX’s target for Starship’s 10th launch

Elon Musk has revealed SpaceX’s target timeline for the next Starship launch, which will be the tenth in program history.

Published

4 weeks ago

on

July 16, 2025

By

Credit: SpaceX

Elon Musk has revealed SpaceX’s target timeline for the next Starship launch, which will be the tenth in program history.

Musk says SpaceX is aiming for a timeline of roughly three weeks from now, which would come about ten weeks after the previous launch.

Coincidentally, it would bring the two launches 69 days apart, and if you know anything about Elon Musk, that would be an ideal timeline between two launches.

SpaceX is coming off a test flight in which it lost both the Super Heavy Booster and the Upper Stage in the previous launch. The Super Heavy Booster was lost six minutes and sixteen seconds into the flight, while SpaceX lost communication with the Ship at 46 minutes and 48 seconds.

Musk is aiming for the tenth test flight to take place in early August, he revealed on X:

This will be SpaceX’s fourth test flight of the Starship program in 2025, with each of the previous three flights bringing varying results.

IFT-7 in January brought SpaceX its second successful catch of the Super Heavy Booster in the chopstick arms of the launch tower. The ship was lost after exploding during its ascent over the Turks and Caicos Islands.

IFT-8 was on March 6, and SpaceX caught the booster once again, but the Upper Stage was once again lost.

The most recent flight, IFT-9, took place on May 27 and featured the first reused Super Heavy Booster. However, both the Booster and Upper Stage were lost.

The Federal Aviation Administration (FAA) hit SpaceX with a mishap investigation for Flight 9 on May 30.

Continue Reading

Trending