Starship Update

Summary

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Everything Everywhere Daily

Episode: “Starship Update”

Host: Gary Arndt
Date: October 20, 2025

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Overview

In this episode, Gary Arndt provides a detailed and engaging update on the development of SpaceX’s Starship—the largest and most ambitious rocket ever built. The main thrust of the episode is exploring how Starship’s pursuit of full reusability represents a paradigm shift in spaceflight, with the ultimate goal of drastically slashing the cost of launching cargo (and people) into orbit and beyond. Gary offers a historical context for the cost of reaching space, a technical breakdown of Starship’s design philosophy, a chronological recap of test flights, and insight into upcoming developments, all while maintaining his signature blend of clarity and curiosity.

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Key Discussion Points & Insights

1. Historical Problem: The Cost of Space Launches

• Disposable Rockets and High Costs

  • For decades, all major rockets have been single-use, making space launches inherently expensive.
  • “[Since] the launch of Sputnik in 1957, launching anything into space has been difficult and expensive, with an emphasis on the expensive.” (03:17)
  • Throughout the 1960s, adjusted for inflation, the cost per kilogram to orbit was around $50,000, and with the Space Shuttle, it even increased to about $54,000 despite its partly reusable design.

• SpaceX’s Falcon 9 & the First Reusability Breakthrough

  • The Falcon 9 dramatically changed the economics of space with a reusable first stage, achieving a 99.5% success rate (548/551 landings as of recording).
  • Cost per kilogram:
    • Falcon 9: ~$2,500
    • Falcon Heavy: as low as $1,500

2. Starship’s Ambition: Full Reusability & Massive Scale

• Starship vs. Past Rockets

  • It’s fully reusable—both first and second stages—unlike any rocket before.
  • It’s physically larger than even the Saturn V rocket that sent people to the Moon.

• Engineering Innovations

  • 33 Raptor Engines: Instead of 5 giant engines (as with Saturn V), Starship uses many smaller ones. The Soviets failed with this approach, but SpaceX has succeeded.
    • “If you lose an engine, it isn’t catastrophic. They’re easier to swap out and refurbish.” (08:13)
  • Mechazilla Launch Tower:
    • Giant arms (“chopsticks”) catch the returning boosters, eliminating the need for landing legs and enabling quick turnaround.
    • “Not only does it support vehicle stacking… [it] also houses giant mechanical arms designed to catch the returning first stage after launch…” (09:45)
  • Reusability aims to drop the cost per kilogram to orbit initially to ~$100, with $10–$20 as a longer-term target.

3. Iterative Test Flights: Failure as an Engineer’s Friend

• Starship’s Testing Philosophy
  • Rapid, iterative, data-driven approach akin to software beta testing: launch, learn, improve, repeat.
  • “The best analogy… is that they’re conducting their engineering similar to how software is often written.” (12:40)
  • Out of 11 test flights to date:
    • 6 considered “loosely successful,” 5 “failures” (all learning experiences).

Test Flight Timeline & Highlights

| Test # | Date | Main Achievements/Notes | |--------|----------------|-------------------------------------------------------------------| | 1 | Apr 20, 2023 | Largest rocket launch ever. Autodestruct after in-flight issues. | | 2 | Nov 18, 2023 | Stage separation achieved, both stages lost. | | 3 | Mar 14, 2024 | Second stage achieved orbital velocity, later broke up. | | 4 | Jun 6, 2024 | Simulated pad landing, ship survived peak reentry. | | 5 | Oct 13, 2024 | Booster caught by Mechazilla; ascent and splashdown succeeded. | | 6 | Nov 19, 2024 | Similar to #5; completed Block 1 operations. | | 7 | Jan 16, 2025 | Block 2 debut; propellant leak led to termination. | | 8 | Mar 6, 2025 | Booster landed; stage 2 lost engines and telemetry. | | 9 | May 27, 2025 | Velocity achieved; propellant leak curtailed mission. | | 10 | Aug 26, 2025 | Deployed dummy satellites; no soft landing after engine failure. | | 11 | Oct 13, 2025 | Almost perfect; both booster and ship achieved soft landing. |

• “What you can see over the course of the tests is the iterative improvement in the rockets. Sometimes it’s one step back and two steps forward, but things are moving forward…” (25:45)

4. Moving Forward: Block Upgrades and Upcoming Milestones

• Block 2 Improvements:

  • Larger propellant tanks, improved flaps, robust heat shields, and modernized avionics—each redesign based on test feedback.

• Block 3 and the Future:

  • Block 3 Debuts in Early 2026
    • Most notable: Version 3 Raptor engines (lighter, more power, integrated wiring, lots of 3D-printed parts for fewer bolts/welds).
    • Further vehicle refinements: refined grid fins, heat shields, propellant/docking systems, refueling hardware.
    • Major milestone planned: First in-orbit fuel transfer, a technique necessary for deep-space missions.
    • Possible “throwaway” missions to the Moon or Mars, exploiting the 2026 Mars launch window.
      • “A Mars mission might just be a Hail Mary pass because Mars happens to have a launch window this year and if they don't try it now, then they'd have to wait another two years.” (32:37)

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Notable Quotes & Memorable Moments

• On Starship’s Place in History:
  • “Starship is the largest rocket ever flown, but it is fundamentally different than all other rockets that have come before it. Its intent is to be fully reusable. This has the potential to completely revolutionize spaceflight.” (00:06)
• On the shift in engineering culture:
  • “Many people have misunderstood the SpaceX approach because they're used to how NASA always does things. The best analogy…is that they're conducting their engineering similar to how software is often written.” (12:40)
• On public engagement:
  • “If you haven't watched any of the launches, I recommend you do so because they're really fun. There are probably over a dozen YouTube channels that provide live coverage of the launches and provide excellent commentary on what's happening.” (34:29)
• On iterative testing:
  • “Sometimes it's one step back and two steps forward, but things are moving forward, which is a lot considering that this is both the largest and most complicated rocket to ever fly.” (25:45)

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Timestamps for Important Segments

• 03:08 — Recap of Starship’s purpose and historical cost context
• 07:11 — Introduction of engineering innovations: Raptor engines, Mechazilla
• 12:40 — SpaceX’s iterative, software-like testing approach
• 13:41 — Detailed breakdown and results of tests #1–6
• 18:06 — Introduction of Block 2 Starship; test results #7–11
• 25:45 — Emphasis on iterative progress and overcoming setbacks
• 28:20 — Description of Block 3 upgrades, Version 3 Raptor improvements
• 32:10 — Future missions: In-orbit refueling, Moon/Mars prospects
• 34:29 — Encouragement to watch launches; cultural impact

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Conclusion

Gary Arndt’s “Starship Update” is a comprehensive, accessible guide to SpaceX’s most ambitious rocket program—clearly laying out both the immense challenges and the exponential gains in reliability, reusability, and cost reduction. He situates the current progress within the larger arc of spaceflight history, encourages curiosity and public engagement, and leaves listeners with the sense that we are experiencing an exciting, pivotal era.

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Transcript

[Narrator / Host]

One of the biggest advances in spaceflight right now is happening with the development of Starship. Starship is the largest rocket ever flown, but it is fundamentally different than all other rockets that have come before it. Its intent is to be fully reusable. This has the potential to completely revolutionize spaceflight and dramatically reduce the cost of bringing cargo to orbit. It's not quite there yet, but it's getting close. Learn more about Starship and its latest advancements on this episode of Everything Everywhere Daily.

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I did my first episode on Starship back In February of 2022 over three and a half years ago. I did a redux episode in January of 2024 where I gave a brief update, but it's necessary for a more comprehensive update on what's happening because there's been a lot of activity. Before I get into the latest developments, let me give a recap of the problem that Starship is trying to solve. Ever since the launch of Sputnik in 1957, launching anything into space has been difficult and expensive, with an emphasis on the expensive. The reason why space has been so expensive is that until recently, all rockets have been disposable. You build an entire rocket, you launch it, and you destroy it in the process, with most of it ending up either at the bottom of the ocean or burning up in the atmosphere. The cost for launching 1 kilogram, or 2.2 pounds, into low Earth orbit were about $50,000 on average in the 1960s, adjusted for inflation. The high cost of launching anything into orbit was the main impetus behind the Space Shuttle program. The idea was that having a mostly reusable vehicle would reduce costs dramatically. If you remember back to my episode on the Space Shuttle, that didn't happen initially. The cost to orbit actually went up with the Space Shuttle. Because of the complexity and fragility of the shuttle, it never came close to achieving its goals for the number of flights it would have. During the entire life of the Shuttle program, The cost per kilogram to low earth orbit averaged about $54,000. Cost actually decreased after the Shuttle program simply because disposable rockets became cheaper. But the real groundbreaking drop in price came with the development of the Falcon X9 rocket by SpaceX. The Falcon 9 was a breakthrough because the entire first stage of the rocket was reusable. Instead of landing horizontally like an airplane, the rocket landed vertically. It was an incredibly challenging engineering problem, but SpaceX managed not only to get it to work, but has now done so 548 times out of 551 attempts as of the recording of this episode, that is a 99.5% success rate. The Falcon 9 booster, with ID number B1067 has been launched a record 27 times. With the Falcon 9, the cost per kilogram to orbit plummeted to about $2,500. With the Falcon 9 heavy variant, the cost can drop to as far as $1,500. That is an incredible reduction in price, but there's still a lot more room for improvement. The second stage of the Falcon 9 still can't be recovered, and the size of the rocket limits the amount that can be launched at any one time, limiting possible efficiencies. Starship is the ultimate goal of SpaceX. It's a fully reusable rocket, and it's also the largest rocket to have ever flown. It is larger than the Saturn V from the Apollo program that sent people to the moon. The goal is initially to reduce the cost per kilogram to get to orbit down to about $100. And depending on how many times they can reuse the components, you it's possible to get that number down to about 10 to $20. In addition to being fully reusable, there are a host of additional innovations that are being implemented. A big one is the number of engines being used. The Saturn V used five enormous F1 rockets on its first stage. Starship uses 33 Raptor engines on its first stage. Using more smaller engines is challenging. The Soviets tried doing this with their Saturn v competitor, the N1, which had 30 engines, but they never got it to fly successfully. Having more engines has benefits. However, it's cheaper to make a smaller engine. If you lose an engine, it isn't catastrophic. They're easier to swap out and refurbish without resulting in downtime. The same Raptor engines are also used on the orbital second stage as well, meaning that you don't need multiple types of rocket engines. They've also created a unique launch tower especially designed for Starship. The launch tower for Starship is known as Mechazilla. Not only does it support vehicle stacking, that being lifting the giant first stage booster and then the second stage ship onto the pad. It also houses giant mechanical arms designed to catch the returning first stage after launch, rather than relying on landing legs and wheels. This approach reduces the mass and complexity of the booster, enables very fast reuse, and allows the rocket to be caught and immediately, immediately returned to the pad for relaunch, representing a fundamental shift in how launch hardware is recovered. Compare this to what NASA did for years, where they had to assemble everything, an enormous building, and then roll every rocket out to the launch pad. So since I did the first Starship episode, SpaceX has had 11 test launches of Starship. Perhaps you've seen them on YouTube where each of them is usually live streamed on multiple space themed channels such as everyday astronaut and NASASpaceflight. The test flights are exactly that. They're designed to test various components and systems. They then take that data they get from those tests and try to implement that data into future launches. Many people have misunderstood the SpaceX approach because they're used to how NASA always does things. The best analogy to what SpaceX is doing is that they're conducting their engineering similar to how software is often written. A software program will often be released in alpha or beta versions to look for bugs and issues that need to be fixed before releasing a final product. Product SpaceX is trying to iterate rapidly launch, find out what went wrong and then do it again as soon as you can. Review the data and implement the changes of the 11 test flights of Starship that have been conducted so far, six can loosely be considered successful and five have been considered failures. And I say quote unquote, because even the failures have been learning experiences. The failures basically mean that the rocket blew up at some point in the flight unexpectedly, or that the flight objectives were not achieved. The first full test of the full stack of the upper and lower stages took place on April 20, 2023. This set the record for the largest rocket launch in history, which was previously set by the Soviet N1 rocket. While the launch was successful, there were problems just a few minutes in and the autodestruct system was activated. Test two came almost half a year later on November 18th. This successfully achieved the separation of the two stages, but both stages were ultimately destroyed. Test three was on March 14th of 2024. It went better. The second stage achieved orbital velocity but broke up over the Indian Ocean. Test 4 was the fastest turnaround yet and took place on June 6th. This was also the best test yet. They simulated a near pad virtual tower booster landing above the Gulf of Mexico and had the ship survive peak heating during RE entry and reached a controlled splashdown corridor in the Indian Ocean. Test 5 was a big one. On October 13th they caught the booster with the chopsticks on Mechazilla and the ship completed ascent and splashdown testing. Test number six was barely a month later on November 19th. It was similar to test five except the ship completed a Raptor engine ignition in space. Another landing on Mechazilla was scrubbed at the last minute. However, test number six completed their block one era. These were the first iterations of both rocket stages and the lessons learned in this phase were then put into a new Design. For Block 2. The new Block 2 version of Starship featured enlarged propellant tanks that increased total capacity and thrust duration. RE engineered aerodynamic flaps with relocated hinges to reduce heating during RE entry, and a more robust heat shield system that used pin tiles, improved insulation and tighter seams for better durability. The interstage and plumbing layouts were simplified for lighter mass and easier maintenance, while avionics and venting systems were modernized for greater reliability. Together, these changes made Block 2 heavier, taller, and far more capable. All of the block two flights took place in 2025. Test seven was on January 16th. The goal was just to repeat tests five and six with the new model, but the ship suffered a propellant leak that cost altitude control and the flight was terminated. Test 8 was on March 6. The booster phase went well and it was able to land on Mechazilla. However, the second stage lost multiple engines and then telemetry, leading to a breakup before the planned objectives were complete. Test nine was on May 27th. This didn't go so well. The ship reached its planned velocity. Then a propellant system leak and loss of altitude control curtailed the mission. The booster also broke up after starting its landing burn. Test 10 was on August 26th. For the first time, Starship managed to deploy dummy satellites. However, an engine hardware failure resulted in the ship not being able to do a soft landing. Test 11 the most recent test so far took place on October 13th. This was the last of the Block 2 tests. It was almost a perfect test which achieved everything it set out to do, including a soft landing of both the booster and the ship. What you can see over the course of the tests is the iterative improvement in the rockets. Sometimes it's one step back and two steps forward, but things are moving forward, which is a lot considering that this is both the largest and most complicated rocket to ever fly. The next flight test, which should begin in early 2026, will be the start of the Block III Starship builds. One of the biggest changes will be the adoption of the version 3 raptor engines. These are actually a remarkable bit of engineering. If you look at a photo of the Version one versus the Version three Raptor engines, they're night and day. The Version one engines look incredibly complicated, with tons of external pipes and tubes. The version 3 engines are smaller, sleeker, yet are more powerful at the same time. Most of the wires and pipes have been integrated into the engine itself, and much of the engine is now being built via 3D printing, which eliminates the need for many bolts and welds. It also simplifies the aft end of the rocket by eliminating most external engine shielding, which isn't necessary with the new design. The booster gets a redesigned forward dome and vented interstage, plus three larger grid fins double as tower catch points. The ship adopts a revised heat shield tile design and dedicated on orbit refueling hardware, including a docking interface and a new quick disconnect. In addition to testing new hardware, the plan is to test new techniques, the biggest of which is to conduct the first fuel transfer in orbit, which has never been done before. This will also result in the first full orbital missions. There's also a chance that specially designed ships which are not intended to return to Earth, might be sent to the moon or Mars in 2026. These would be tests to see if they can land remotely on another body and then take off again. A Mars mission might just be a Hail Mary pass because Mars happens to have a launch window this year and if they don't try it now, then they'd have to wait another two years. That being said, a moon mission might not take place until 2027 and nothing has been made public as of yet. There's still a lot of work to be done on Starship and I'm sure I'll be doing yet another follow up episode at some point in the future, but things are most definitely happen and they are going in the right direction. If you haven't watched any of the launches, I recommend you do so because they're really fun. There are probably over a dozen YouTube channels that provide live coverage of the launches and provide excellent commentary on what's happening. This is one of the most exciting times in spaceflight since at least the start of the shuttle program way back in the early 1980s. The executive producer of Everything Everywhere Daily is Charles Daniel. The associate producers are Austin Otkin and Cameron Kiefer. My big thanks go to everyone who supports the show over on Patreon. Your support helps make this podcast possible, and I also want to remind everyone about the community groups on Facebook and Discord. That's where everything happens that's outside the podcast, and links to those are available in the show Notes. As always, if you leave a review on any major podcast app or in the above community groups, you too can have it read on the show.