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SpaceX rolls naked Starship prototype to test site

Ship 26 joins Ship 25 for proof testing. (NASASpaceflight - Starbase Live)

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SpaceX has rolled a strange, naked Starship prototype from its Starbase, Texas factory to a nearby test site.

Beginning with its cone-tipped nose section, SpaceX started stacking Starship S26 in October 2022. By early January 2023, the prototype had been stacked to its full 50-meter (~165 ft) height and welded together. After about six more weeks of outfitting, Ship 26 left Starbase’s High Bay assembly facility and was transported to one of two stands formerly used for suborbital Starship test flights.

SpaceX lifted Ship 26 onto Suborbital Pad A on the morning of February 12th. Just a few hundred feet to the left, Starship prototype S25 watched from Suborbital Pad B while waiting for the start of its Raptor engine test campaign. Ship 26 is four months younger than Ship 25 and rolled out without Raptors installed, as it still needs to pass several simpler tests. That’s far from the only difference between the Starships.

Starbullet

Aside from a range of smaller design changes, Ship 26 has three main differences relative to most prior Starships. First, it has zero heat shield tiles. Since the 2020-2021 period of suborbital Starship flight testing, all finished ships (S20, S21, S22, S24, S25) have been fitted with ~10,000 black, ceramic heat shield tiles. Eventually, those tiles will (theoretically) protect Starships from the intense heat created by reentering Earth’s atmosphere at orbital velocity.

Ship 26 also has no flaps. Since SpaceX first fully assembled a Starship in October 2020, every ship the company has completed (SN8, SN9, SN10, SN11, SN15, SN16, S20, S21, S22, S24, S25) has had four large flaps and form-fitting ‘aerocovers’ installed. Starships need flaps to steer and orient themselves during orbital reentries. They also need flaps to control themselves during exotic landing maneuvers, which require ships to free-fall belly-down (like a human skydiver) and aggressively flip into a vertical orientation for propulsive landings.

Starship SN8 demonstrates the ‘bellyflop’ and flip maneuvers, which need flaps to ensure stability. (Richard Angle)
Beginning with Ship 20, all Starship flaps and bodies have been covered in thousands of heat shield tiles. (Richard Angle)

Finally, and most confusingly, Ship 26 has no payload bay of any kind. The end result is a smooth, featureless Starship that looks like a steel bullet, can’t return to Earth, and can’t deploy satellites. Combined, the fact it exists at all almost seems like an elaborate, multi-month mistake. But SpaceX clearly intended to build Ship 26 and is now preparing to qualify it for flight.

Depot, Moon lander, or something else?

In simpler terms, Ship 26 is an intentionally expendable Starship with no way to launch satellites. That raises the obvious question: why does it exist? There are a few obvious possibilities. SpaceX is developing at least four types of Starships. The Crew and Tanker Ships will have heat shields and flaps. The Starship Moon lander will have no flaps or heat shield and will be painted white and insulated. A Depot Ship with stretched tanks will stay in orbit permanently and store propellant for in-space refilling.

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Based on low-resolution renders, the bullet-like Depot Ship is the most reminiscent of Ship 26. However, there’s no evidence that Ship 26 has “exterior optical properties [optimized] for long duration [propellant storage].” The prototype also lacks any of the hardware likely needed for docking or propellant transfer and has propellant tanks that are the same size as past ships. To survive in orbit for days or weeks, it would need some kind of power source – typically solar arrays – that isn’t present. And even if an expendable Starship like S26 can already achieve SpaceX’s reported target of 250 tons (~550,000 lb) to low Earth orbit, 250 tons is only a fifth of a full propellant load.

The Starship variants required for SpaceX’s NASA Moon landing contracts. (NASA)

Ship 26 could also be used for miscellaneous systems testing or a longevity demonstration in orbit. However, it’s unclear why SpaceX couldn’t simply do that with Ship 24 and Ship 25. Both have had their payload bays permanently sealed, meaning that they are only useful as test articles. The same is true for a tank-to-tank propellant transfer test SpaceX received a NASA contract to conduct in 2020. During that test, Starship will transfer “10 metric tons” of cryogenic liquid oxygen (LOx) between its main LOx tank and a smaller header LOx tank used to store landing propellant. But all Starships built to date have header tanks and could be used for the same test.

Ship 26 could exist primarily to demonstrate that a Starship with no flaps or heat shield tiles is aerodynamically stable during launch. However, expending an entire Starship for what amounts to wind tunnel testing would be extravagant.

Preparing for flight

Regardless, Ship 26 is clearly destined for more than the scrapyard. The bullet-like prototype was installed on Suborbital Pad A, which SpaceX has modified for cryogenic proofing and structural testing. While coordinating with Ship 25, which needs to conduct static fire tests, Ship 26 will be pressurized and loaded with liquid nitrogen, liquid oxygen, or both to safely simulate the thermal and mechanical loads it will experience when filled with propellant. The stand is fitted with hydraulic rams that can simultaneously simulate the thrust of six Raptor engines (1380 tons / 3M lbf).

If it passes those tests, SpaceX will presumably return Ship 26 to the Starbase factory for Raptor installation. Strangely, the smooth Starship isn’t alone. It appears that Ship 27 will be more or less identical, with no heat shield or flaps. However, there’s evidence that Ship 27 will have the first working payload bay on a Starship and could be used to deploy full-size Starlink V2 satellites in addition to any other testing SpaceX wants to use it for.

The most exotic (and unlikeliest) explanation for Ship 26 and Ship 27 is that the pair is meant to support SpaceX’s first Starship docking and propellant transfer test. In October 2022, a NASA official indicated that SpaceX’s second Starship test flight would be a “Starship-to-Starship propellant transfer.”

For now, SpaceX’s priority is preparing Ship 24 and Super Heavy Booster 7 for Starship’s first orbital launch attempt, followed by preparing Ship 25 and Booster 9 for the second orbital test flight. Until then, Ship 26 and Ship 27 will likely remain a bit of a mystery.

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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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SpaceX readies Starship Flight 14 for a historic journey into uncharted territory

SpaceX finished Starship’s Flight 14 rehearsal, clearing the way for its first orbital flight Monday.

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Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX
Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX

SpaceX has cleared one of the last hurdles before Starship’s first trip to orbit. The company posted on X Thursday afternoon that its launch rehearsal for Flight 14 was complete, keeping the mission on track for Monday, September 28. The launch window opens at 7:15 a.m. CT at Starbase, Texas, and runs for 75 minutes.

A wet dress rehearsal is essentially launch day without the launch. Crews fill Booster 21 and Ship 41 with thousands of tons of extremely cold propellant, run the countdown nearly to ignition, then drain everything back out. It lets engineers catch leaks or equipment problems before anything leaves the pad. SpaceX still needs a launch license from the FAA before the stack, which stands 407 feet tall, can fly.

Flight 14 matters because of where it is going. All 13 previous Starship flights followed a suborbital path, which works like throwing a ball extremely high and far: the vehicle reaches space, but it is always on a course that brings it back down within about an hour. This time, Ship 41 will perform a short engine firing called an orbital insertion burn roughly 25 minutes after liftoff, giving it enough speed to keep falling around Earth instead of back into it. SpaceX plans about six laps at an altitude near 275 kilometers (171 miles) over nearly 10 hours, as Teslarati detailed when the mission was first announced.


Getting into orbit also means Starship has to prove it can get back out. The ship must relight a single Raptor engine in space to slow down for reentry. SpaceX says it will only attempt the orbital insertion burn after flight controllers confirm the hardware needed for that return burn has enough backup, and its flight plan includes health checks that could shorten the mission to two or five orbits.

Flight 14 is also the first to put working satellites into service. Flight 13 carried 20 Starlink V3 satellites in July, but they came back down with the ship because that mission never reached orbit. This time, 26 V3 satellites are meant to stay up and join the constellation within a few weeks. Together they add about 26 terabits per second of network capacity, which SpaceX says is roughly 10 times what a single Falcon 9 launch of older V2 Mini satellites adds. Three of them carry cameras that will photograph Starship’s heat shield in orbit to check for tile damage before reentry.

The hardware has changed too. Ship 41 flies with extra fasteners on tiles in the most vulnerable areas, fixes for gaps where superheated plasma slipped behind tiles, and curved tiles designed to reduce heating between them. Two tiles recovered from Ship 40 will fly again, the first reuse of any part of a Starship heat shield. Booster 21 carries better engine filtering and new relight software after ice clogged three center engines on the previous booster, leaving only eight of 13 engines to restart for its landing burn.

Ship 41 is targeting a splashdown in the Pacific Ocean west of Chile, a new recovery zone after several Indian Ocean landings, while Booster 21 aims for the Gulf. Neither will be caught by the tower on this flight. Elon Musk said in August that a ship catch was likely “in a few months.”

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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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