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SpaceX set to finish three Starship prototypes in the same month

The tank sections of two full-scale Starship prototypes stand side by side as they speed towards completion. (NASASpaceflight - bocachicagal)

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SpaceX appears to be on track to complete its third Starship prototype in a month just days after the company finished testing a new steel tank and at the same time as it prepares to roll another full-scale ship to the launch pad.

Postponed by several weeks after the (fleeting) success of the Starship serial number 4 (SN4) prototype, violently destroyed by a minor testing mishap on May 29th, SpaceX’s fifth full-scale Starship tank section (SN5) could roll to an adjacent testing facility at any point in the next few days. In fact, SN4’s successor has likely been ready to begin tank proof and static fire testing for several weeks since it was stacked to its full height on May 12th. SN4 rolled to the launch pad on April 23rd and remained SpaceX’s top Starship priority until its demise more than a month later.

As it turns out, the explosion that destroyed the ship also launched a ~25 metric ton (~55,000 lb) counterweight installed a few days prior some 100m (300+ ft) into the air, where it proceeded to fall back to earth and obliterate the steel mount Starship SN4 sat on. The loss of that pad hardware necessitated its own several-week delay but SpaceX appears to be nearly done installing and outfitting replacements as of June 18th – an incredible turnaround given the scale and complexity of everything involved. Of course, the whole purpose of those rapid repairs is to get back to the business of testing Starships as quickly as possible.

SpaceX recently finished stacking Starship SN6’s tank section barely a month after its predecessor – and did so side by side. (NASASpaceflight – bocachicagal)

SN5

Initially expected as early as 8am local on June 17th, Starship SN5’s trip to the launch pad has been a long time coming. Completed around May 20th after approximately a month of concerted effort, the ~30m (100 ft) tall tank departed SpaceX’s Vehicle Assembly Building (VAB) for the first on June 13th, although it was quickly moved back inside as technicians simultaneously worked to complete Starship SN6.

Previously scheduled to become the first Starship to reach its full height with the installation of a functional nosecone, SN5 will likely pick up where SN4 left off, instead. That process will effectively be no different, albeit sans nosecone, starting with ambient and cryogenic proof (pressure) tests and eventually moving to one or several static fires with either one or three Raptor engines. Testing the quick disconnect umbilical port that caused SN4’s demise will also likely be a priority. If all goes according to plan in that first week or two of tests, SpaceX may finally be ready to launch a full-scale Starship prototype for the first time, performing a 150m (~500 ft) hop test with SN5.

Starship SN5 steps out of its perch inside the VAB for the first time since assembly began. (NASASpaceflight – bocachicagal)

However, since CEO Elon Musk first discussed plans for an initial 150m hop test, SpaceX received a surprise suborbital launch license from the FAA, rather than the limited experimental permit most expected. That license effectively allows SpaceX to perform an unlimited number of Starship tests as long as the trajectory follows the administration’s strict safety guidelines and remains suborbital. Unless SpaceX’s ~150m target was based in some technical limitation, the sky is quite literally the limit for a more ambitious flight debut if the company believes Starship SN5 can handle it.

SN6

In the event that Starship SN5 follows its predecessor into a less early (but still early) grave, SpaceX thankfully won’t have to wait long at all to continue its hardware-rich test program. When Starship SN5 first departed the VAB on June 13th, it did so to give SpaceX room to finish Starship SN6, placing its aft engine section on a stand inside the building and stacking the upper two-thirds of the ship’s tank on top.

Starships SN5 and SN6, May 23rd. (NASASpaceflight – bocachicagal)
Starships SN5 and SN6, June 7th. (NASASpaceflight – bocachicagal)
Starships SN5 and SN6, June 16th. (NASASpaceflight – bocachicagal)

Several days to a week or more of internal and external work remain to fully mate the two Starship SN6 sections, but the vast majority of its assembly is now behind SpaceX. SpaceX continues to refine its methods with each successive prototype, gradually producing Starships that are getting closer and closer to the ideal finished product. There’s a chance that, unlike Starship SN4, SN5 can be modified with the installation of a nosecone and flaps to support more ambitious 2-20 km (~1.2-12 mi) flight tests if it makes it over the 150m hurdle unscathed but if not, SN6 could become the first Starship to have a nosecone installed.

SN7

Last but absolutely not least, SpaceX recently built a new Starship test tank for the first time since March. While stouter than an actual Starship-class methane or oxygen tank, this particular test tank is maybe only 25% shorter than the methane tanks installed on Starship prototypes. According to Musk and effectively confirmed by writing all over the prototype, this particular test tank – formerly Starship SN7 – was built to determine if a different kind of steel could be preferable for future ships.

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Starship SN7 survived its first cryogenic pressure test largely unscathed despite developing a leak mid-test. (NASASpaceflight – bocachicagal)
Leak be damned, the SN7 test tank was quickly repaired and will likely be tested again in the next few days. (NASASpaceflight – bocachicagal)

Shortly after the June 15th test began to wind down, Musk announced that the new material (304L stainless steel) had performed quite well, reaching 7.6 bar (110 psi) before it sprung a leak. The fact alone that it sprung a leak instead of violently depressurizing is already a major sign that 304L is preferable to 301L, as it means that Starships built out of it could fail much more gracefully in the event of a leak instead of collapsing or violently exploding. A step further, SpaceX has already managed to repair the leak on SN7 and will likely test the tank again in the next few days.

Meanwhile, Musk says that a second improved 304L test tank is already on its way, after which SpaceX will likely attempt to build and test the first fully-304L Starship prototype. Further down the line, SpaceX intends to develop its own custom steel alloy, optimized specifically for Starship’s needs. The first tests of that ’30X’ alloy could begin as early as August 2020 according to a February Musk tweet.

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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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Investor's Corner

SpaceX reports its second earnings today: here’s what to expect

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Credit: SpaceX

SpaceX (NASDAQ: SPCX) will report its second public earnings call today since its IPO earlier this year, and there are a few things we expect to hear about, as well as Wall Street analysts, who have already outlined their expectations for the call.

Wall Street analysts have a consensus of $12.72 billion in revenue and an earnings per share (EPS) of $0.13. These are broken down into three sectors: Space, Connectivity, and AI/SI, which are perceived in this way:

  • Space: $1.41 billion
  • Connectivity: $4.84 billion
  • AI/SI: $6.47 billion

Other outlets cluster near $12.8 or $12.9 billion in revenue and $0.14 – $0.15 EPS. This implies a roughly 65 percent sequential growth from Q2’s $7.81 billion, driven mostly by AI/SI, with the first post-IPO positive EPS expected.

SpaceX just launched its secret Starfall saucer again

Here are the three things to watch for on the call:

AI Revenue Ramp and the $100B+ ARR target

AI is truly the swing factor for SpaceX, and analysts expect it to roughly double from Q2’s $2.56 billion and become about half of total revenue. Management previously guided to a $100 billion+ annualized run rate by December, including the Cursor acquisition, which was $60 billion, to close the quarter.

SpaceX makes first acquisition post-IPO

Listen for updates on SpaceX’s compute capacity, especially pertaining to its contracts with Google, Anthropic, and others, revenue per watt, any new deals, and Cursor’s early contribution.

Starlink/Connectivity Metrics and Mobile Expansion

Connectivity remains a main profit engine for SpaceX. Subscriber additions will be something to pay attention to, as Q2 ended at 12 million and previews are looking at 14 million for this quarter. Additionally, ARPU trends, enterprise and government growth, and any commentary on Starlink Mobile will be something to pay attention to, especially following the recent low-band spectrum deal and FCC-related constellation approvals.

Capex Trajectory, Cash Burn/FCF, and Starship/Operational Updates

Q2 capex of roughly $18.4 billion weighed on the stock. Investors will look to scrutinize Q3 spending levels, any guidance on the pace into Q4/2027, free cash flow, backlog, and liquidity. Operational color on Starship (Flight 14 milestones and Flight 15 timing/reusability progress), Falcon cadence, and government/NASA contracts are also in focus.

Of course, there will also be some speculation on the potential Tesla-SpaceX merger, but there was nothing mentioned in the company’s proxy it sent earlier this week.

SpaceX will report earnings after market close today and will stream the call on X.

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SpaceX just launched its secret Starfall saucer again

SpaceX launched its Starfall capsule again on Bandwagon-5, this time listed openly beside rideshare customers.

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An artist’s illustration of a SpaceX Starfall capsule reentering Earth’s atmosphere. (Image: SpaceX)
An artist’s illustration of a SpaceX Starfall capsule reentering Earth’s atmosphere. (Image: SpaceX)

SpaceX launched its Starfall reentry capsule for the second time on Tuesday morning, flying it as the payload of the Bandwagon-5 rideshare mission. Falcon 9 lifted off from Space Launch Complex 40 in Florida at 7:04 a.m. ET with 32 payloads, and the first stage booster, on its 19th flight, landed on the droneship A Shortfall of Gravitas about nine minutes later.

Starfall was scheduled to separate last, 2 hours and 48 minutes after liftoff. The final customer satellite on SpaceX’s mission timeline comes off the upper stage about an hour and nine minutes in, which left a long gap before the capsule was due to be released alone. SpaceX later posted that the payload deployment sequence is complete. At liftoff, the company said Starfall “enables affordable, routine access to a microgravity environment, providing unique opportunities for on-orbit manufacturing, scientific research, and testing.”

As Teslarati reported before the first Starfall flight, SpaceX made no public announcement about the vehicle then, and nearly everything known came from FAA and FCC filings. This time Starfall is an item name on the official mission page, listed beside paying rideshare customers. SpaceX has still not said what, if anything, is aboard this Starfall, Spaceflight Now noted.

The FAA’s environmental assessment from May describes a disk about 10.2 feet wide and 2.5 feet tall that weighs roughly 4,600 pounds and can bring 2,200 pounds of payload back to Earth.

Interestingly, the same rocket also carries a competitor’s hardware. Varda Space Industries launched its W-Series 7 capsule on Bandwagon-5, a spacecraft about three times smaller than Starfall that will test whether microgravity can improve the solubility of a cancer drug called Protac. It is Varda’s ninth reentry capsule, and W-8 and W-9 launched earlier this month on Transporter-18. SpaceX has been Varda’s launch provider since the company’s first Falcon 9 rideshare contract in 2021.

SpaceX has not published where or how this Starfall will come down. The preview we ran in June described a recovery from the Pacific Ocean, and the company has not said whether this flight follows the same plan. The launch also arrives hours before SpaceX posts its third quarter results after the market closes, a report we previewed earlier this week.

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The Boring Company’s latest Tesla tunnel truck mod “fits like a glove”

The Boring Company has modified a Tesla powered tunnel truck to carry freight containers underground.

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The Boring Company has found a second job for the Tesla hardware it already runs underground. In a post on X, Elon Musk’s tunneling company showed its latest Prufrock Liner Truck modified to carry a standard 20 foot shipping container. “Using TBC tunnels to transport freight,” the company wrote. “The latest Prufrock Liner Truck (using Tesla Model 3 batteries and drive units) has been modified to carry a standard 20′ shipping container. Fits like a glove!”

The photo shows a red container sitting on a long, low white chassis parked outside, with drive hardware visible at one end. The Boring Company did not say where or when freight hauling would start, which customers it has in mind, or how many trucks it is converting.

Until now, the liner trucks have hauled concrete. Teslarati reported in August on Liner Truck 3, which uses Model 3 battery packs and drive units to move more than 22,000 pounds of precast tunnel segments to the boring machine. It has 28 miles of range, tops out at 12 mph, and is piloted remotely from the company’s operations center in Texas. The freight version appears to be the same platform with a different bed, and The Boring Company has not said whether it will also be remotely piloted.

Freight has been on the company’s menu for years. When TBC updated its product lineup in 2021, its freight tunnel was described as sized to fit a standard shipping container, “barely.” The company later used the idea at Tesla’s own factory, where Prufrock 3 dug a tunnel to Giga Texas that now moves finished Cybertrucks away from the production line.

The Boring Company closed a $3 billion Series D in September at a $23 billion valuation, and Teslarati has covered how that money is tied to a UAE tunneling push and a faster Nashville build. In Nashville, Prufrock MB1 and MB2 are mining at the same time, and a third machine is expected to launch in late October. Each machine needs a steady supply of liner trucks, so any design that works for segments and containers alike gives the company more use out of the same Tesla parts.

The Vegas Loop remains the only Boring Company system open to the public, and it moves passengers in Tesla vehicles. A freight service would be a separate product, and the post gave no indication that one is close to launch. For now, it is a truck, a container and a short caption saying they fit together.

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