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SpaceX Super Heavy booster returns to launch pad after major repairs

Booster 7 has returned to the orbital launch site after suffering damage a few weeks prior. (NASASpaceflight - bocachicagal)

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3 years ago

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SpaceX has returned its newest Super Heavy to Starbase’s orbital launch site (OLS) after rapidly repairing damage the booster suffered during its first round of testing.

Super Heavy Booster 7 (B7) left the High Bay it was assembled in for the first time on March 31st and rolled a few miles down the road to nearby Starship launch and test facilities on a set of self-propelled mobile transporters (SPMTs). On April 2nd, the roughly 67-meter-tall (~220 ft; 69m w/ Raptors) rocket was installed on top of Starbase’s lone orbital launch mount (OLM), setting the stage for crucial qualification testing.

The start of that process was exceptionally successful. On April 4th, after a smooth launch mount installation, SpaceX quickly filled Booster 7’s propellant tanks with a relatively benign cryogenic fluid (liquid nitrogen, liquid oxygen, or both) to simulate the thermal and mechanical characteristics of real flammable propellant. Despite the fact that the test marked the first time SpaceX had fully filled a Super Heavy prototype’s tanks, Booster 7 sailed through the ‘cryoproof’ without any obvious issue.

On April 8th, SpaceX moved Super Heavy B7 from the orbital launch mount to a structural test stand that had been installed and modified just a few hundred feet away in the weeks prior. This is where Booster 7’s near-perfect start to qualification testing took a bit of a turn. Booster 7 is only the third full-size Super Heavy prototype SpaceX has tested since July 2021. Like Booster 3 and Booster 4 before it, Booster 7 features some major design changes that ultimately make the prototype a pathfinder, necessitating extensive qualification testing.

To name just a few of the changes, Super Heavy B7 is the first booster fitted with a 33-engine puck and the first finished Starship prototype of any kind designed to use new Raptor V2 engines. With all 33 engines installed and operating a full thrust, Booster 7’s entire structure – and its aft thrust section especially – would be subjected to around 40% more thrust and stress than Booster 4, which indirectly completed structural testing with the help of a sacrificial test tank. Beyond differences in thrust and mechanical stress, Booster 7 is also the first Super Heavy to reach the test stand with secondary ‘header’ tanks meant to store landing propellant.

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It’s unclear if those header tanks were fully filled and drained during Booster 7’s cryoproof, but they would not be quite as cooperative during a different kind of cryogenic testing on the structural test stand. The stand SpaceX modified specifically for Super Heavy B7 was outfitted with 13 hydraulic rams to simulate the full thrust of the booster’s central Raptor V2 engines – up to almost 3000 tons (~6.6M lbf) compared to Booster 4’s ~1700 tons (~3.7M lbf) with a smaller cluster of nine engines.

Implosion at the Structural Test Stand

After a few false starts and minor tests on the stand, Booster 7 finally managed some significant testing on April 14th. Judging by the rhythmic shattering of ice that built up on Super Heavy’s tanks, the test stand was able to simulate the thrust of Raptors to some degree and subject the booster to major mechanical stress that was felt from tip to tail. Within a few days, Booster 7 was removed from the test stand and returned to the high bay on April 18th. Around April 21st or 22nd, an image was leaked showing extensive damage inside Booster 7, confirming that the Super Heavy’s test campaign had been forced to end prematurely.

A leaked image looking up inside B7’s LOx header tank after testing. Above, B7’s aft section and LOx header before the booster was fully assembled.

Right away, the damage shown in the photo hinted at an operational failure, meaning that mistakes made by the rocket’s operators may have been more to blame than a possible design flaw. The photo shows a short portion of B7’s liquid methane (LCH4) transfer tube that runs through the booster’s new liquid oxygen (LOx) header tank, which itself sits inside Super Heavy’s main LOx tank at the aft end of the rocket – a tube inside a small tank inside a large tank, in other words. Super Heavy’s LCH4 transfer tube generally does what it says, allowing methane to safely fly down through the main LOx tank and fuel up to 33 Raptor engines. At full thrust, that tube would need to supply around 20 tons (~45,000 lb) of methane per second.

However, on top of merely transferring methane through the oxygen tank, Booster 7 introduced a design change that allows some or all of that tube to change functions and become a header tank mid-flight. That would require a system of valves that could seal off the main LCH4 tank once it was emptied, turning the transfer tube into a sort of giant steel straw filled with enough LCH4 to fuel Super Heavy’s boost-back and landing burns.

The damaged transfer tube in the leaked photo of Booster 7 doesn’t look that unlike what one might expect to see if they sucked through one end of a straw while blocking the other end, collapsing the center. Translated to the scale of Super Heavy, after an otherwise successful day of structural testing, SpaceX operators may have accidentally closed or opened the wrong valves while draining the booster’s transfer tube of liquid oxygen or nitrogen. As the heavy liquid drained from the tube, a lack of pressure equalization could have quickly drawn a vacuum and caused the tube to implode.

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On April 29th, a SpaceX fan turned analyst published an analysis that convincingly pinpointed the moment Booster 7’s transfer tube collapsed. Simultaneously, because it showed that the transfer tube likely imploded during detanking, the analysis more or less confirmed the above speculation that the failure had been caused by a degree of operator error or poor test design. Of course, it’s possible that a hardware or software design flaw contributed to or caused the anomaly or that something like a pressure differential in the LOx header tank and LCH4 header tube could also explain the damage, but the accidental formation of a vacuum during detanking is arguably the simplest (obvious) explanation.

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After the image of the internal damage leaked, the immediate consensus among fans and close followers was that Booster 7 was beyond repair. Instead, SpaceX appears to have proven those assumptions wrong and somehow managed to repair the upgraded Super Heavy to the point that it was worth testing again less than three weeks after returning to the high bay. On May 6th, B7 was rolled back to the launch site and installed, for the second time, on the orbital launch mount.

Prior to the failure, the general expectation was that SpaceX would begin installing Raptor V2 engines as soon as Booster 7 passed structural testing. It remains to be seen if SpaceX wants to repeat Booster 7’s cryoproof or structural testing to ensure that its quick repairs did the job before proceeding into static fire testing as previously planned. Nonetheless, hope lives on for the Super Heavy prototype and new test windows have been scheduled from 10am to 10pm on May 9th, 10th, and 11th.

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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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Elon Musk roasts owners of this car brand after another Tesla vandalism incident

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5 hours ago

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March 16, 2025

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Elon Musk roasted owners of one specific car brand after yet another incident of a Tesla being vandalized, this time in New York.

Tesla owners have had a bit of a target on their backs in recent months as Musk, CEO of the company, has joined forces with U.S. President Donald Trump in an effort to eliminate excessive and unneeded government spending in the new Department of Government Efficiency, or DOGE.

Due to Musk’s bold personality and unfiltered political beliefs, he has gained plenty of critics in the last few months. Tesla owners are being targeted as a result, seeing their vehicles be vandalized on nearly a daily basis.

Tesla-owned showrooms across the country have also been the target of some attacks, as one was even damaged in a series of shootings, another lit on fire by a Molotov cocktail.

Nevertheless, Musk has continued to stand firm on his beliefs, and Tesla drivers are getting fed up with the amount of damage being done to their cars. In this particular instance, someone drew a swastika on the side of a New York City Tesla Cybertruck owner. He was able to confront the person who drew the offensive logo, an exchange that was caught on camera:

The video was shared on X, which grabbed the attention of Musk, who was sure to criticize the make of the assailant’s vehicle: a Subaru.

Musk said:

“Crazy people. Naturally, he drives a Subaru …”

The playful jab at Subaru drivers likely comes from the stereotype that those vehicles are usually driven by people with intense political and social beliefs. Facetious posts on Reddit claim that Subarus won’t operate without at least ten bumper stickers on them. Subaru’s past marketing and advertising campaigns have attracted those who are “outdoorsy,” Google’s AI description of the drivers states.

Musk has never held back and never will. In an interview with MSNBC, he said he will speak his mind and if his companies lose money because of it, “so be it.” One thing is for sure, Musk is not going to shy away from speaking or posting how he pleases.

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Tesla stores continue to face anti-Musk protests

Scenes from a protest outside of Tesla’s store in Loveland, Colorado.

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19 hours ago

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March 15, 2025

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Tesla stores have been the target of widespread protests and vandalism in recent weeks, after Elon Musk made a controversial gesture in January, and as he and the Trump administration’s newly created government efficiency division continues to gut federal agencies.

On Saturday, I went to the Tesla store in Loveland, Colorado, where demonstrators were already protesting upon my arrival at roughly 12:45 p.m. MT.  Walking up to the protest, I could see scattered groups of demonstrators lined up along about two blocks, spanning from the Tesla store to a nearby intersection and Sprouts location. One protestor said he had counted about 230 people at around 1:00 p.m. MT.

The protest felt generally peaceful, with cars driving by and honking, and demonstrators leaving a large space between the front of the Tesla store and the sidewalk, easily allowing workers and customers to go in and out.

You can see a few videos and photos from the site below, along with some of the responses I got from protestors and a prospective customer.

READ MORE ON TESLA PROTESTS AND VANDALISM:

I spoke to about a dozen protestors about what they were protesting against. Most said they were there to condemn Musk’s recent federal worker and program cuts with the Trump administration, his performance of what some said resembled a Nazi salute at Trump’s inauguration ceremony in January, or the administration’s recent attacks against transgender and queer individuals.

One protestor, Elsa, identified as a former Republican and said she was “highly concerned that our Constitution is being ignored,” especially with regards to the three branches of government and the system of checks and balances.

“It surprises me that, even if you voted for Trump, or you believe in capitalism, which, I didn’t vote for Trump, but I do believe in capitalism — I’m a former Republican, I was a Republican for most of my life — but it’s dangerous to have power rest in a handful of ultra-wealthy people,” Elsa said.

“And our whole country needs to realize that,” she adds. “This to me is not even Republican or Democrat at this point.”

Instead, she says it now comes down to whether people want to give billionaires huge tax breaks, or to use that money to support a range of groups in the U.S., including those who have social security benefits, are veterans, or are 9/11 survivors seeking cancer treatments, as a few examples.

Another protestor, Mary, said she was taking part in the demonstration “because she loves this country and democracy,” adding that she wanted to help preserve democracy for her grandchildren.

Still another protestor, Bryan, said that they were protesting because of the Trump administration and Musk’s attempts to erase transgender, non-binary, and queer people from history, drawing comparisons to the rise of fascism in Nazi Germany, where early human rights violations were lodged against gay and queer communities.

“I’m here because I have to be,” Bryan said. “I’m afraid of the future.”

Yet another person and his family were holding Ukraine flags, saying that they were protesting for a wide range of reasons, but especially for Trump’s recent meeting with Ukraine President Volodymyr Zelenskyy and Musk’s claims that the top Ukrainian executive was to blame for what he has called a “forever war.”

While most protestors appeared to be generally friendly, especially with each other, I did hear a few exchanges between demonstrators and those with other opinions. While I heard more cars honking throughout the experience, seemingly in support of the protests, I also noticed a few from which passengers yelled things like “Go Trump.”

“Direct action, we need to stop these fascists with direct action,” one protestor yelled in response.

Additionally, I also talked to a prospective customer, Kristy, who was there for a test drive and said she had a negative experience with the protestors.

“I was test driving a Tesla, and as we pulled in and parked right here, this black one, these people right here in the middle yelled at me, ‘Hope you’re turning in your f*cking Nazi car,’ and I said ‘F*ck you,’” Kristy explained.

“And they’re like ‘F*ck you too, you’re a Nazi, f*cking Nazi lovers.’ And so, they’re just yelling racial slurs at me, and I’m far from a Nazi.”

Tesla store advisers declined to comment on the protests, and so did Loveland police.

Other Saturday protest footage from Tesla stores in California, Texas, and New York

The Loveland Tesla store has also been the site of repeated attacks in recent weeks, with authorities on Friday making a second arrest following multiple incidents. You can see the Department’s press release for the arrest below.

The protest was also part of widespread demonstrations on Saturday, and it’s just the latest in actions targeting Musk’s electric vehicle (EV) company, some of which have included acts of vandalism, graffiti, arson, and even the use of weapons on Tesla storefronts.

Multiple other protests were also captured in footage on Saturday, including one in Santa Rosa, California, as shared by the San Francisco Chronicle, and another attended by conspiracy theorist Alex Jones in Austin, Texas. Still another was captured in New York City, and you can see footage from each of these protests below.

Tesla vandalism cases under investigation by FBI Seattle

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Musk sets a date for Starship trip to Mars with Optimus on board

Optimus could be the first humanoid to make it to Mars, and Musk has set a date for when he thinks it’ll happen.

Published

1 day ago

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March 15, 2025

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Credit: SpaceX

Elon Musk has shared when he expects to take Starship to Mars for its first uncrewed mission, and he also says Tesla’s Optimus humanoid robot will be on board for the flight.

On Friday, Musk wrote on X that SpaceX’s reusable Starship rocket will take Optimus to Mars at the end of 2026, with human landings expected to commence a few years later.

“Starship departs for Mars at the end of next year, carrying Optimus,” Musk said. “If those landings go well, then human landings may start as soon as 2029, although 2031 is more likely.”

Last year, the SpaceX and Tesla head also said he expected that SpaceX would be able to begin uncrewed launches in 2016, with early launches including both Optimus and a Cybertruck unit.

Musk also followed up the announcement with a post on X on Saturday morning, noting that he expects SpaceX to launch more than 90 percent of Earth’s payload mass to orbit this year. Meanwhile, he says China will make up just around 5 percent, while the rest of the world, including other parts of America, would also make up just 5 percent.

He also predicted that the number would go up even further to nearly 100 percent, once SpaceX’s reusable rocket is being launched more frequently.

“When Starship is launching at high rate, SpaceX will probably carry >99 percent of Earth’s payload mass to orbit. This is necessary to make Mars a self-sustaining civilization,” Musk added.

READ MORE ABOUT SPACEX’S STARSHIP: Texas awards SpaceX $17.3M grant to expand Bastrop tech hub

To be sure, Musk has been known to make ambitious claims about when his companies’ products would achieve certain milestones. For example, Musk predicted in 2018 that SpaceX could launch a rocket to Mars with humans aboard by 2024, though SpaceX only began testing the company’s reusable Starship in 2023.

Still, the company has been routinely testing Starship since then, and with increasing frequency, and in October, SpaceX performed the first catch of the Starship’s Super Heavy booster after liftoff to demonstrate the concept that a reusable rocket could be possible. In a launch earlier this month, SpaceX again successfully caught the Super Heavy Booster, though it lost the upper stage to a “rapid unscheduled disassembly,” effectively meaning that it had exploded in air and showered surrounding areas with rocket parts.

The explosion was the second consecutive launch in which debris from Starship reigned down, highlighting the continued importance of testing as SpaceX aims to make the rocket a viable product for reusable space travel.

On Friday, SpaceX also launched its Crew Dragon spacecraft to the International Space Station (ISS) to rescue astronauts that have been stuck on the orbital craft, after a Boeing Starliner craft was originally intended to bring them back to Earth. While SpaceX attempted to rescue the two astronauts in September, issues with the Crew Dragon craft’s thrusters discovered upon arrival made NASA hold off on approving the return mission.

Update 3/16/25: Edited final paragraph after incorrectly saying that Starliner had been a SpaceX craft, rather than one owned by Boeing.

SpaceX completes a new first with recent Falcon 9 launch

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