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SpaceX first Super Heavy ‘test tank’ is almost ready for prime time

The latest in a long line of Starship 'test tanks' is almost ready to head to the launch pad. (NASASpaceflight - bocachicagal)

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SpaceX has almost completed a ‘test tank’ meant to ensure that Starship’s Super Heavy booster is capable of withstanding the immense thrust of more than two-dozen Raptor engines.

Believed to be known as test tank BN2.1, the prototype’s latest appearance comes on the heels of news from CEO Elon Musk that SpaceX has upgraded Super Heavy with one extra Raptor engine – with plans to add another three down the road. The results of that tank’s imminent test campaign will likely be crucial as the company shifts its focus sending Starship to orbit (or close) as soon as possible.

Prior to a new Super Heavy booster ‘thrust puck’ design first spotted on May 29th, at least two separate booster engine section prototypes completed in the last few months sported an earlier variant more akin to a donut. At that point, Super Heavy’s design had a central cluster of eight gimballing, throttleable Raptors surrounded by a ring of 20 Raptor Boost (“RBoost”) engines – a variant meant to trade the ability to throttle for ~25% more thrust.

A massive Super Heavy ‘thrust puck’ sporting a new design was first spotted in Boca Chica on May 29th. (NASASpaceflight – bocachicagal)

While Super Heavy booster BN1’s almost immediate scrapping – prior to a single test – guaranteed that major design changes were on the way, exactly what those changes would be was anyone’s guess. The appearance of a new booster ‘thrust puck’ design and Musk’s subsequent announcement that Super Heavy will “initially” have 29 – not 28 – Raptors likely mean that that engine section redesign was a major contributor to BN1’s instant obsolescence. The only other major change SpaceX clearly made with booster BN2 was switching the positions of its liquid methane and liquid oxygen tanks, ensuring that Super Heavy’s heavier oxidizer is closer to the rocket’s base.

Musk also stated that SpaceX will eventually upgrade Super Heavy to 32 engines, giving future boosters a central cluster of 12 engines that the SpaceX CEO says will significantly improve the efficiency of boostback burns.

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With 29 identical Raptors, the simplest possible Super Heavy booster would produce up to 5800 tons (12.8M lbf) of thrust at liftoff. If SpaceX has already completed Raptor Boost’s design and qualification and kicked off mass production of a 250-mTf engine, that liftoff thrust climbs to 6800 tons (~15M lbf). If SpaceX achieves performance goals (~210 mTf stock; ~300 mTf RBoost) mentioned by Musk last year, a 32-engine Super Heavy could achieve peak liftoff thrust greater than 8500 metric tons (~18.7M lbf).

Even in its weakest configuration, Super Heavy will still be more than 60% more powerful than Saturn V and 25% more powerful than N1 – the largest rockets to have ever successfully or unsuccessfully flown. That immense thrust demands a structure capable of surviving those extreme forces while simultaneously feeding dozens of Raptors up to ~28 metric tons (~61,000 lb) of propellant every second and withstanding several thousand tons of liquid oxygen – all without leaking, cracking, or flexing too much.

Vents on top of the forward dome are a telltale sign of a test tank. (NASASpaceflight – Nomadd)
SpaceX has modified an existing structural test stand to support BN2.1’s test campaign. (NASASpaceflight – bocachicagal)

While BN2.1 wont have any of the plumbing associated with dozens of Raptors, nine hydraulic rams will let SpaceX subject its Super Heavy thrust structure to the simulated thrust of some number of engines. Given the presence of nine rams and nine clustered engines, it’s unclear if BN2.1 will only test that main thrust structure or if those rams will somehow be spread out to simulate the thrust of a full 29 engines – 20 of which will instead transfer most or all of their thrust into Super Heavy’s skirt.

Regardless, if successful, BN2.1’s test campaign should leave SpaceX on track to attempt Starship’s inaugural spaceflight as early as Q3 2021. If issues arise, that target could easily slip to Q4 or into 2022, but SpaceX’s test tank campaigns have historically been very successful.

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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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Tesla already has a complete Robotaxi model, and it doesn’t depend on passenger count

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

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Credit: @AdanGuajardo/X

Tesla already has the pieces in place for a full Robotaxi service that works regardless of passenger count, even if the backbone of the program is a small autonomous two-seater. 

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

Two-seat Cybercabs make perfect sense

During the Q&A portion of the call, Tesla Vice President of Vehicle Engineering Lars Moravy pointed out that more than 90% of vehicle miles traveled today involve two or fewer passengers. This, the executive noted, directly informed the design of the Cybercab. 

“Autonomy and Cybercab are going to change the global market size and mix quite significantly. I think that’s quite obvious. General transportation is going to be better served by autonomy as it will be safer and cheaper. Over 90% of vehicle miles traveled are with two or fewer passengers now. This is why we designed Cybercab that way,” Moravy said. 

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Elon Musk expanded on the point, emphasizing that there is no fallback for Tesla’s bet on the Cybercab’s autonomous design. He reiterated that the autonomous two seater’s production is expected to start in April and noted that, over time, Tesla expects to produce far more Cybercabs than all of its other vehicles combined.

“Just to add to what Lars said there. The point that Lars made, which is that 90% of miles driven are with one or two passengers or one or two occupants, essentially, is a very important one… So this is clearly, there’s no fallback mechanism here. It’s like this car either drives itself or it does not drive… We would expect over time to make far more CyberCabs than all of our other vehicles combined. Given that 90% of distance driven or distance being distance traveled exactly, no longer driving, is one or two people,” Musk said. 

Tesla’s robotaxi lineup is already here

The more interesting takeaway from the Q4 and FY 2025 earnings call is the fact that Tesla does not need the Cybercab to serve every possible passenger scenario, simply because the company already has a functional Robotaxi model that scales by vehicle type.

The Cybercab will handle the bulk of the Robotaxi network’s trips, but for groups that need three or four seats, the Model Y fills that role. For higher-end or larger-family use cases, the extended-wheelbase Model Y L could cover five or six occupants, provided that Elon Musk greenlights the vehicle for North America. And for even larger groups or commercial transport, Tesla has already unveiled the Robovan, which could seat over ten people.

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Rather than forcing one vehicle to satisfy every use case, Tesla’s approach mirrors how transportation works today. Different vehicles will be used for different needs, while unifying everything under a single autonomous software and fleet platform.

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Tesla Cybercab spotted with interesting charging solution, stimulating discussion

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

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Credit: What's Inside | X

Tesla Cybercab units are being tested publicly on roads throughout various areas of the United States, and a recent sighting of the vehicle’s charging port has certainly stimulated some discussions throughout the community.

The Cybercab is geared toward being a fully-autonomous vehicle, void of a steering wheel or pedals, only operating with the use of the Full Self-Driving suite. Everything from the driving itself to the charging to the cleaning is intended to be operated autonomously.

But a recent sighting of the vehicle has incited some speculation as to whether the vehicle might have some manual features, which would make sense, but let’s take a look:

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

Now, it is important to remember these are prototype vehicles, and not the final product. Additionally, Tesla has said it plans to introduce wireless induction charging in the future, but it is not currently available, so these units need to have some ability to charge.

However, there are some arguments for a charging system like this, especially as the operation of the Cybercab begins after production starts, which is scheduled for April.

Wireless for Operation, Wired for Downtime

It seems ideal to use induction charging when the Cybercab is in operation. As it is for most Tesla owners taking roadtrips, Supercharging stops are only a few minutes long for the most part.

The Cybercab would benefit from more frequent Supercharging stops in between rides while it is operating a ride-sharing program.

Tesla wireless charging patent revealed ahead of Robotaxi unveiling event

However, when the vehicle rolls back to its hub for cleaning and maintenance, standard charging, where it is plugged into a charger of some kind, seems more ideal.

In the 45-minutes that the car is being cleaned and is having maintenance, it could be fully charged and ready for another full shift of rides, grabbing a few miles of range with induction charging when it’s out and about.

Induction Charging Challenges

Induction charging is still something that presents many challenges for companies that use it for anything, including things as trivial as charging cell phones.

While it is convenient, a lot of the charge is lost during heat transfer, which is something that is common with wireless charging solutions. Even in Teslas, the wireless charging mat present in its vehicles has been a common complaint among owners, so much so that the company recently included a feature to turn them off.

Production Timing and Potential Challenges

With Tesla planning to begin Cybercab production in April, the real challenge with the induction charging is whether the company can develop an effective wireless apparatus in that short time frame.

It has been in development for several years, but solving the issue with heat and energy loss is something that is not an easy task.

In the short-term, Tesla could utilize this port for normal Supercharging operation on the Cybercab. Eventually, it could be phased out as induction charging proves to be a more effective and convenient option.

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Tesla confirms that it finally solved its 4680 battery’s dry cathode process

The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

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tesla 4680
Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years. 

The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

Dry cathode 4680 cells

In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.

The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”

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Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.

4680 packs for Model Y

Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla: 

“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”

The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.

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