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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.

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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.

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.

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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 FCC just said ‘No’ to SpaceX for now

SpaceX is fighting the FCC for spectrum that could put satellites inside every smartphone.

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SpaceX was dealt a new setback on April 23, 2006 by the Federal Communications Commission (FCC) after the U.S. government agency dismissed the company’s petition to access a Mobile Satellite Service spectrum that would allow direct-to-device (D2D) capabilities.

The FCC regulates communications by radio, television, wire, and cable, which also includes regulating D2D technology that lets your existing smartphone connect directly to a satellite orbiting Earth, the same way it would connect to a cell tower.

Elon Musk’s SpaceX has been building toward this through its Starlink Mobile service, formerly called Direct-to-Cell, in partnership with T-Mobile. The service officially launched on July 23, 2025, starting with messaging and expanding to broadband data in October of that year.

T-Mobile Starlink Pricing Announced – Early Adopters Get Exclusive Discount

It’s worth noting that SpaceX is not alone in this race. AT&T and Verizon have their own satellite texting deals with AST SpaceMobile, while Verizon separately offers free satellite texting through Skylo on newer phones.

The regulatory foundation for all of this dates to March 14, 2024, when the FCC adopted the world’s first framework for what it called Supplemental Coverage from Space, allowing satellite operators to lease spectrum from terrestrial carriers and fill gaps in their coverage. On November 26, 2024, the FCC granted SpaceX the first-ever authorization under that framework, approving its partnership with T-Mobile to provide service in specific frequency bands. SpaceX then went further, completing a roughly $17 billion acquisition of wireless spectrum from EchoStar, which gave it the ability to negotiate with global carriers more independently.

Starlink’s EchoStar spectrum deal could bring 5G coverage anywhere

This recent ruling by the FCC blocked SpaceX from going further, protecting incumbent spectrum holders like Globalstar and Iridium. But the market momentum is already in motion. As Teslarati reported, SpaceX is targeting peak speeds of 150 Mbps per user for its next generation Direct-to-Cell service, compared to roughly 4 Mbps today, which would bring satellite connectivity close to standard carrier performance.

With a reported IPO targeting a $1.75 trillion valuation on the horizon, each spectrum fight, carrier deal, and regulatory win or loss now carries weight beyond just connectivity. SpaceX is quietly becoming the infrastructure layer underneath the phones of millions of people, and the FCC’s next move will help determine how much further that reach extends.

FCC Satellite Rule Makings can be found here.

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Elon Musk

SpaceX just got pulled into the biggest Weapons Program in U.S. history

SpaceX joins the Golden Dome software group, deepening its role in America’s most expensive defense program.

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US Golden Dome space defense system (Concept render by Grok)

SpaceX has joined a nine-company group developing the core operating software for the Golden Dome, America’s next-generation missile defense system. According to a Bloomberg report, SpaceX is focused on integrating satellite communications for military operations and is working alongside eight other defense and artificial intelligence companies, including Anduril Industries, Palantir Technologies, and Aalyria Technologies, to build software connecting missile defense capabilities.

The Golden Dome concept dates back to President Trump’s 2024 campaign, and on January 27, 2025, he signed an executive order directing the U.S. Armed Forces to construct the system before the end of his term. The system is planned to employ a constellation of thousands of satellites equipped with interceptors, with data centers in space providing automated control through an AI network.

FCC accepts SpaceX filing for 1 million orbital data center plan

Space Force Gen. Michael Guetlein, director of the Golden Dome initiative, has described the software layer as a “glue layer” that would enable officers to manage and control radars, sensors, and missile batteries across services. The consortium is aiming to test the platform this summer.

Trump selected a design in May 2025 with a $175 billion price tag, expected to be operational by the end of his term in 2029, though the Congressional Budget Office projected the cost could reach $831 billion over two decades.

The Golden Dome role is only the latest in a string of military wins for SpaceX. As Teslarati reported, the U.S. Space Force awarded SpaceX a $178.5 million task order on April 1, 2026 to launch missile tracking satellites for the Space Development Agency, covering two Falcon 9 launches beginning in Q3 2027. That came on top of more than $22 billion in government contracts held by SpaceX as of 2024, per CEO Gwynne Shotwell, spanning NASA resupply missions, classified intelligence satellites through its Starshield program, and military broadband.

The accumulation of defense contracts, now including a seat at the table on the most expensive weapons program in U.S. history, positions SpaceX as the dominant infrastructure provider for American national security in space. With a SpaceX IPO still on the horizon, each new contract adds weight to what is already one of the most consequential companies in aerospace history, raising real questions about how much of America’s defense architecture will depend on a single private operator before it ever trades publicly.

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SpaceX is following in Tesla’s footsteps in a way nobody expected

In the span of just months in early 2026, SpaceX has transformed itself into one of the world’s most ambitious AI companies. The catalyst: its February acquisition of xAI.

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Credit: Grok

When Elon Musk founded Tesla in 2003, it was a plucky electric car startup betting everything on lithium-ion batteries and a niche luxury Roadster.

Two decades later, Tesla is far more than a car company. Its valuation increasingly hinges on Full Self-Driving software, the Optimus humanoid robot, the Robotaxi program, and the Dojo supercomputer cluster purpose-built for AI training.

Musk has repeatedly described Tesla as an AI and robotics company that happens to sell vehicles. The cars, in this view, are merely the first scalable platform for real-world AI.

Now, SpaceX is tracing an eerily similar path, only faster and in a direction almost no one anticipated. Founded in 2002 to make spaceflight routine and eventually multiplanetary, SpaceX spent its first two decades perfecting reusable rockets, landing Falcon 9 boosters, and building the Starlink megaconstellation.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

It was an engineering and manufacturing powerhouse, not a software play. Yet, in the span of just months in early 2026, SpaceX has transformed itself into one of the world’s most ambitious AI companies. The catalyst: its February acquisition of xAI.

The xAI deal, announced on February 2, was structured as an all-stock transaction that valued the combined entity at roughly $1.25 trillion—SpaceX at $1 trillion and xAI at $250 billion. In a memo to employees, Musk framed the merger as the creation of “the most ambitious, vertically-integrated innovation engine on (and off) Earth.”

The new SpaceX now owns Grok, the large language model family that powers the chatbot of the same name, along with xAI’s massive training infrastructure. More importantly, it has a declared mission to move AI compute off-planet.

Earth-based data centers are hitting hard limits on power, cooling, and land. Musk’s solution is orbital data centers, or constellations of solar-powered satellites that act as supercomputers in the sky.

SpaceX has already asked regulators for permission to launch up to one million such satellites. Starship, the company’s fully reusable heavy-lift vehicle, is the only rocket capable of delivering the necessary mass at the required cadence.

Each orbital node would enjoy near-constant sunlight, vast radiator surfaces for passive cooling, and zero terrestrial real-estate costs. Musk has predicted that within two to three years, space-based AI inference and training could become cheaper than anything possible on the ground.

This is not a side project; it is the strategic centerpiece Musk has envisioned for SpaceX. Starlink already provides the global low-latency backbone; next-generation V3 satellites will carry onboard AI accelerators. Rockets deliver the hardware, while AI optimizes every aspect of launch, landing, and constellation management.

The feedback loop is self-reinforcing, too. Better AI makes better rockets, which launch more AI infrastructure.

Just yesterday, on April 21, SpaceX doubled down.

It secured an option to acquire Cursor—the fast-growing AI coding tool beloved by software engineers—for $60 billion later this year, or pay a $10 billion partnership fee if the full deal does not close.

Cursor’s models already help engineers write code at superhuman speed. Pairing that technology with SpaceX’s Colossus-scale training clusters (the same ones powering Grok) positions the company to dominate AI developer tools, much as Tesla dominates autonomous driving software.

Why SpaceX just made a $60 billion bet on AI coding ahead of historic IPO

The parallels with Tesla are striking. Both companies began in a single, capital-intensive sector: Tesla with EVs, SpaceX with launch vehicles. Both used early hardware success to fund AI at scale. Tesla’s Dojo supercomputers train neural nets on billions of miles of real-world driving data; SpaceX now trains on telemetry from thousands of orbital assets and re-entries.

Tesla’s FSD chip runs inference on cars; SpaceX’s future satellites will run inference in orbit.

Tesla’s Optimus robot will work in factories; SpaceX envisions lunar factories manufacturing more AI satellites, eventually using electromagnetic mass drivers to fling them into deep space.

Critics once dismissed Musk’s multi-company empire as unfocused. The 2026 moves reveal the opposite: deliberate convergence.

SpaceX is no longer merely a rocket company that sells internet from space. It is an AI company whose competitive moat is literal orbital infrastructure and the only vehicle that can service it at scale. The forthcoming IPO, expected later this year, will almost certainly be pitched not as a space play but as the purest bet on AI infrastructure the public market has ever seen.

Whether the orbital data-center vision survives regulatory scrutiny, astronomical concerns about light pollution, or the sheer engineering challenge remains to be seen.

Yet the strategic direction is unmistakable. Just as Tesla proved that software and AI could redefine the century-old automobile, SpaceX is proving that rockets are merely the delivery mechanism for the next great computing platform—one that floats above the clouds, powered by the sun, and limited only by the physics of orbit.

In that unexpected sense, history is repeating. Tesla stopped being “just a car company” years ago. SpaceX has now stopped being “just a rocket company.” Both are becoming something far larger: AI powerhouses with hardware moats so deep that competitors will need their own reusable megaconstellations to keep up.

The age of terrestrial AI is ending. The age of space-based AI is beginning—and SpaceX is building the launchpad.

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