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SpaceX fully installs Super Heavy booster’s ‘aerocovers’

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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.

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.

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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.

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 flight set to make history on Friday the 13th

SpaceX is targeting Friday, November 13 for Starship Flight 15 and its first ship catch.

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SpaceX is targeting Friday, November 13 for Starship Flight 15, the mission the company plans to use for its first attempt at catching the ship itself with the launch tower.

SpaceX Vice President of Launch Kiko Dontchev shared the date on stage at the UP.Summit on Thursday, according to Ars Technica’s Eric Berger, who was in attendance. It is the first launch target to come directly from a SpaceX executive. Until now, the public schedule had relied on FAA air traffic planning slides, which listed Flight 15 for no earlier than November 8 and later November 12. SpaceX has not posted an official mission page yet, and no launch time has been shared.

The date lands inside the window Elon Musk sketched out last month. Speaking at Giga Texas on October 10, Musk said the flight would “probably launch a little bit before Thanksgiving,” as Teslarati reported. On SpaceX’s third quarter earnings call ten days later, he confirmed that Flight 15 would try to catch both the Super Heavy booster and the ship, and put the odds of a successful ship catch at “more likely than not.” SpaceX also aired an animation of the maneuver during that webcast, showing the ship swinging vertical over Starbase before dropping into the tower’s chopsticks.

The hardware is ready. Booster 22 fired all 33 of its Raptor engines for a full duration static fire at Pad 2 on October 25. Ship 42 followed with a single engine burn simulating a deorbit maneuver on October 26 and a 60 second firing of all six engines the next day, according to NASASpaceflight. Ship 42 had already rehearsed the catch in September, when the Pad 2 arms lifted it into position and crews connected the quick disconnect arm while the vehicle hung from the tower.

The remaining hurdle is regulatory. The FAA’s Starship page does not yet list a Flight 15 license. SpaceX President Gwynne Shotwell said in October that, after “significant constructive engagement with the FAA,” she expects the license to cover a return to the launch site and a tower catch for both stages. Bringing the ship home means a reentry path that heads toward land, rather than ending over open ocean as every Starship flight so far has.

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SpaceX has caught Super Heavy three times, on Flights 5, 7 and 8, but the ship comes back from orbital velocity and has never been caught. Flight 14 on September 28 was the first Starship to reach orbit, deploying 26 Starlink V3 satellites before splashing down despite an early engine shutdown that Musk blamed on engine computer software.

Musk has called a successful ship catch “the first time that there’s been full recovery of an orbital class rocket,” and he has already named the step after it: a Flight 16 where both the booster and the ship fly again. NASASpaceflight reports that Ship 43, the next vehicle in line, is set for static fire testing in December.

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Investor's Corner

Musk’s Tesla and SpaceX decline after Democratic Midterm sweep

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Credit: Grok

Tesla and SpaceX shares fell on Wednesday after Democrats swept both chambers of Congress. The decline stood out as broader market securities recovered and turned positive, while both of Musk’s publicly traded companies lagged.

CEO Elon Musk already joked about the unsuccessful campaigning for the Republicans, but now the new party will make pretty drastic changes to how it handles Tesla and SpaceX, and those companies will adjust their outlook.

Elon Musk hilariously comments on Midterm election results

Let’s take a deeper look.

Tesla ($TSLA)

Tesla shares traded lower during the regular session after Democrats secured both the House and Senate. The stock was down 2.32 percent at around 1:45 p.m. on the East Coast, trading at around $389.30.

The pressure is tied to more than the raw scale of Musk’s political spending, estimated at $450–474 million this cycle with roughly $224 million directed at Texas. In that state, Tesla now faces a Democratic governor and a Democratic senator after Gina Hinojosa unseated Greg Abbott and James Talarico defeated Ken Paxton.

The Austin Gigafactory, Robotaxi pilot programs in multiple Texas cities, and any related AI compute expansion sit under a new state executive who campaigned against certain corporate subsidies and floated a moratorium on new data-center construction.

Federally, Democratic control of key committees opens the door to deeper examination of Tesla’s autonomous-driving safety record, federal energy-storage and manufacturing incentives, and the national-security implications of any combination with SpaceX.

Investors are also weighing whether the company’s historically close alignment with the prior Republican leadership will invite slower permitting, additional hearings, or tighter rules on Full Self-Driving deployment.

For Tesla, the political shift adds near-term friction around state permitting and federal regulatory approvals for autonomy and energy storage. A potential merger with SpaceX may face slower review even if it proceeds.

Core growth drivers such as vehicle deliveries, energy deployments, and robotaxi rollout remain intact, yet the stock now carries a higher political-risk premium that could weigh on valuation until the company demonstrates workable relationships with the new Texas leadership and congressional majorities.

SpaceX ($SPCX)

SpaceX shares also declined in live trading on November 4 following the Democratic midterm sweep. The stock traded at $134.97, down 4.49 percent. The drop occurred even as broader indexes stabilized, highlighting a company-specific reaction to the election outcome.

Musk’s large contributions, concentrated in Texas races that both companies lost, place SpaceX’s Starbase launch facility and headquarters under a new Democratic governor.

At the federal level, Democratic control of Congress enables greater scrutiny of NASA, the Department of Defense, and other contracts that support a meaningful share of revenue, along with reviews of Starlink national-security uses and any Tesla merger. Analysts have noted that empowered committees can hold hearings and request documents on these relationships.

For SpaceX, the results raise the risk of delayed contract awards, higher compliance costs, and tighter constraints on AI and satellite infrastructure expansion, particularly in Texas where a data-center moratorium has been discussed.

A merger with Tesla could encounter political friction that slows integration of launch, connectivity, and autonomy capabilities.

While Starlink growth and launch cadence continue as primary drivers, the company faces a more contested path for federal funding and state-level operations, requiring management to rebuild ties with the new congressional majorities and Texas leadership to limit the overhang.

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News

SpaceX moves to challenge AT&T, Verizon with Qualcomm-powered 5G

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Credit: Qualcomm

SpaceX has selected Qualcomm Technologies to supply core infrastructure for Starlink Mobile’s planned nationwide terrestrial 5G network in the United States.

Announced on November 4, the multi-year agreement covers radios, baseband units, and commercial-grade Layer 1 software based on Qualcomm’s Dragonwing Cellular Infrastructure platforms, specifically the QRU100 and QDU100:

These will power Massive MIMO radio units featuring 64 transmit and 64 receive paths (64T64R), designed to boost coverage, capacity, and spectral efficiency at scale. Qualcomm has described the pact as its largest 5G deal to date, with deployment across tens of thousands of U.S. cell sites scheduled to begin in 2027.

The terrestrial build-out is meant to complement, not replace, Starlink’s satellite direct-to-cell capabilities. SpaceX has assembled substantial spectrum holdings for this purpose: roughly 65 MHz of mid-band frequencies acquired from EchoStar (including AWS-4 and related bands) and up to 14 MHz of low-band 800 MHz spectrum from Grain Management.

The low-band airwaves improve indoor penetration and range, while mid-band supports higher capacity. SpaceX executives, including President Gwynne Shotwell, have outlined a hybrid architecture in which satellites eliminate outdoor dead zones and terrestrial nodes add capacity where demand is highest.

Earlier comments suggested small cells or femtocells potentially co-located with existing Starlink user terminals on roofs, though later filings also reference more conventional antennas on towers and structures.

The big picture is SpaceX’s bid to become a full-fledged U.S. mobile carrier rather than a satellite partner or dead-zone filler. AT&T, Verizon, and T-Mobile together generate hundreds of billions in annual wireless revenue; Shotwell has said SpaceX expects to win customers by offering superior coverage, including during disasters, through seamless satellite-terrestrial handoff.

Verizon, AT&T and T-Mobile are trying to shut Starlink out before FCC vote

Starlink already represents a major share of SpaceX’s revenue and profit following the company’s 2026 IPO. By vertically integrating spectrum, satellite manufacturing, launch capacity, and now ground radio equipment, SpaceX aims to control more of the connectivity stack.

Qualcomm’s involvement also positions the network for future evolution toward AI-native 6G infrastructure, with energy-efficient processing that could improve deployment economics.

Challenges remain: spectrum depth still lags the Big Three, capital costs for tens of thousands of sites will be substantial, and regulatory approvals continue, but the Qualcomm deal marks a concrete step from spectrum accumulation toward operational network build-out.

In short, the partnership accelerates Starlink Mobile’s shift from orbital broadband specialist to hybrid mobile competitor, testing whether a space-based company can reshape terrestrial wireless economics and coverage in the world’s largest market.

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