SpaceX ramps up production for next-gen Starship vehicles eyeing 2026 maiden flights

SpaceX is ramping up its production efforts for the next iteration of its Starship vehicles at the Starfactory facility located in Starbase, Texas. Currently, the company is working on various phases of assembly for vessels, including up to Ship 48. The spotlight now shifts to the initial two Block 3 vehicles, which are expected to undertake their maiden flights in 2026.

These vehicles are undergoing meticulous evaluations of their Thermal Protection System (TPS) tiles, essential for withstanding the high temperatures encountered during atmospheric reentry. This phase will include returns to the launch site for a tower catch, marking a significant transition into the Block 3 era.

The first mission featuring the complete Block 3 setup is scheduled for a launch window beginning in March 2026, pending the outcomes of vehicle tests and the operational status of Pad 2 at the Starbase facility. This flight is poised to represent a pivotal shift from the previous Block 2 architecture to an upgraded version that boasts improved performance, enhanced reusability, and is powered by the new Raptor 3 engines.

At the seemingly bustling Starfactory, significant activity has been observed surrounding the assembly of nosecones for future vehicles. Ship 40, now designated for Flight 13, has recently had its nosecone attached to the payload area, with teams actively installing forward flaps and affixing heatshield tiles. Drilling activity has also been noted along the lower rows of the nosecone’s tiles, hinting at ongoing preparations for inspection, potential replacements, or other necessary adjustments. This focused work is critical, as these tiles have been in place for an extended timeframe, and the specific attention directed towards the lower rows suggests a response to insights derived from flight data or quality assurance protocols.

Though no tiles have yet been removed, the ongoing efforts, which have persisted for nearly two weeks, might affect Ship 40’s timeline for moving to Mega Bay 2 for further integration and final preparations. In contrast, newer nosecones designated for Ships 41 and 42 do not exhibit similar issues, indicating that the complications may be tied to earlier installations or specific areas of design.

To further accelerate production, SpaceX has recently introduced new robotic platforms designed to aid in the precise installation of pins that secure heatshield tiles. One nosecone that lacks tiles is already being worked on with this advanced equipment, suggesting a quicker pace for mounting tiles on upcoming vehicles.

The influx of various aerodynamic components, including flaps for the forward and aft sections, into the Starbase facility indicates that SpaceX is stockpiling parts in anticipation of a surge in vehicle assembly throughout 2026. This strategy supports the company’s broader objective of increasing launch frequency, which is fundamental to achieving its ambitious goals that include orbital refueling demonstrations and participation in NASA’s Artemis lunar missions, alongside future endeavors aimed at Mars exploration.

Preparations for Flight 12 are also underway, with Ship 39 stationed inside Mega Bay 2, where extensive scaffolding has been set up to facilitate TPS inspections and potential tile-related work. Recent movements of Composite Overwrapped Pressure Vessels (COPVs) from the production line to the test facility may hint at earlier modifications for Ship 39, potentially based on insights gleaned from testing anomalies experienced by previous spacecraft.

Although Ship 39 is nearing readiness for cryotesting, some final work still needs to be completed at the test site. The timeline for its launch now looks to be aiming for a window in February or, more realistically, March. The next major milestone will involve Booster 19 heading to the test facility for cryotesting, marking an important point for this flight given the setbacks faced during testing of the original booster.