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BN1 was the first Super-Heavy Booster prototype, a pathfinder that was not intended for flight tests.^[16] Sections of the ~66 m (217 ft) tall test article were manufactured throughout autumn 2020.^[2] Section stacking began in December 2020.^[17] BN1 was fully stacked inside the High Bay on March 18, 2021,^[18] and was scrapped on March 30, 2021.^[3]

Booster 3 completed stacking in the High Bay on June 29, 2021,^[19] and moved to the test pad without engines.^[20] A cryogenic proof test was completed on July 13, 2021.^[21][22] Three engines were subsequently added.^[23]

A static fire test was conducted on July 19, 2021.^[8] BN3/Booster 3 was partially scrapped on August 15, 2021, while the LOX tank remained welded to the Test Stand.^[9] The LOX tank was taken off the Test Stand on January 13, 2022.^[24]

Booster 4 first became visible on July 3, 2021. Musk ordered several hundred SpaceX employees at Hawthorne to relocate to Boca Chica to accelerate the development of SN20, BN4, and Orbital Launch Mount A (OLM A)^[23] in an attempt to put the Starship system on OLM A by August 5, 2021.^[23] BN4 was fully stacked on August 1, with a full complement of 29 engines installed on August 2, 2021.^[25] Grid fins were added to support atmospheric reentry testing.

SN20 was stacked on top of Booster 4 on August 6, 2021 for a fitting test, making it the tallest rocket ever fully integrated,^[26] until September 5, 2023, when S25 was stacked onto B9. Booster 4 was then returned to the High Bay for secondary wiring. On September 9, 2021, Booster 4 came again to the launch site on top of OLM A.^[27] B4 completed its first cryogenic proof test on December 17, 2021,^[28] and a pneumatic proof test on December 19, 2021. It underwent another cryogenic proof test and a full-load cryogenic proof test. B4 and Ship 20 were then retired.^[22]

On March 6, 2024, B4s grid fins were removed.^[29] It was moved to the Mega Bay on March 21, 2024,^[30] where it was scrapped on March 22.^[31]

Parts for B5 were observed as early as 19 July 2021.^[11] Stacking for BN5 completed in November, although on 8 December 2021, B5 was retired alongside SN15 and SN16. It was later scrapped.

B6 was converted into Test Tank B6.1.^[32]

B7 was placed on the orbital launch mount on March 31, 2022. After completing a cryogenic proof test on April 4, it was placed on OLS cryogenic station on April 8. B7 completed another cryogenic test on April 14, 2022, but the downcomer suffered a failure and ruptured, and it was returned to the production site for repairs four days later. On May 5, B7 was again placed on the orbital launch mount, where it completed two cryogenic tests on May 9 and May 11, before being moved back to Mega Bay 1 for engine and grid fin installation.^[33] On July 11, 2022, after returning to OLM A for engine testing, B7 experienced a detonation underneath the engines during an attempted 33 engine spin prime test.^[34] The booster was then rolled back to Mega Bay 1.^[35] On August 4, 2022, B7 was transported back to the orbital launch pad with only the 20 outer Raptor engines,^[36] and completed its first single-engine static fire test on August 9. B7 completed a 20-second static fire on August 11, 2022, the longest static fire on a Starship prototype to date.^[37] Following these successful tests, it returned to the production site to receive the remaining 13 engines.^[38] B7 was lifted back on the OLM A on August 23, 2022,^[39] using the chopsticks.^[39] It conducted a series of spin prime and static fire tests throughout August and September,^{[40][41][42][43]} before again returning to the Mega Bay on September 21, 2022.^[44] After receiving additional upgrades it was again lifted on the launch pad on October 8, 2022.^[45] Ship 24 was stacked on top B7 on October 12, 2022,^[46] and was removed after completing multiple cryogenic load tests.^[47][48][49] B7 then completed a spin prime test of multiple engines on November 12, 2022,^[50] and a 14 engine static fire test on November 14, 2022,^[51] and finally an 11 engine static fire in an autogenous pressurization test on November 29, 2022.^[52] On December 9, 2022, B7 rolled back to Mega Bay 1^[53] for further shielding. In January 2023, Booster 7 was rolled back to the launch site where it was stacked with Ship 24 on OLM A for partial and full Wet Dress Rehearsals^[54] before Ship 24 was detached and sent to the Rocket Garden for final TPS work. On February 9, 2023, Booster 7 attempted a 10-second duration 33-engine static fire where 31 of the 33 engines successfully fired for the full duration.^[55] One of its engines was disabled just before testing, and one engine shutdown prematurely. On April 20, 2023, Booster 7 was launched on Integrated Flight Test 1, being destroyed before stage separation after a fire in the aft section severed connections between its engines and flight computers, resulting in a loss of attitude control and FTS activation.^[56]

The first part of B8, the engine thrust puck, was spotted on October 5, 2021. Other parts for B8 were observed on February 3, 2022.^[57] The booster was fully stacked on July 8, 2022.^[58] It was moved to the launch site on September 19, 2022, though it was not tested there.^[59] Booster 8 was scrapped in January 2023 in favor of Booster 9. Booster 8's hydraulic power units were used to replace Booster 7s, along with several other parts, including the engine shielding.^[60][61]

B9 finished stacking in late 2022, and featured upgrades, including electric thrust vector control (ETVC) gimbaling system of the raptor engines, replacing the previous hydraulic power units that were used up to Booster 8. It was moved to the OLS cryogenic station on December 15.^[62] Two cryogenic proof tests were conducted on December 21 and December 29, both of which were successful.^[62] B9 was rolled back to Mega Bay 1 on January 10, for engine installation.^[62] On July 20, Booster 9 was rolled to the launch site, and lifted onto OLM A in preparation for its testing campaign.^[63] On July 23 Booster 9 performed a cryogenic proof test on OLM A,^[62] followed by a spin prime test on August 4.^[62] On August 6, Booster 9 fired 29 engines for 2.7 seconds, instead of the planned 33 engines for 5 seconds. It was then moved off of OLM A and rolled back to Mega Bay 1, where its vented interstage was added on August 16.^[62] B9 was moved back to OLM A on August 22 and underwent another spin prime test the next day.^[62] On August 25, Booster 9 underwent a static fire of all 33 engines, with two engines shutting off early, which lasted around 6 seconds.^[62] Ship 25 (S25) was lifted onto B9 for the first time on September 5, and was destacked several times throughout the rest of the month and mid October.^[62] On October 22, B9 underwent two partial cryogenic tests, while S25 was not tested,^[62] followed by a full wet dress rehearsal (WDR) two days later.^[62] On October 26, S25 was removed from B9 for flight termination system (FTS) installation.^[62] On November 9, B9's FTS was installed, followed by S25 being restacked onto B9,^[62] and then destacked on November 11.^[62] S25 was restacked onto B9 for Flight Test 2 on October 15, ^[64] though a failed grid fin actuator on B9 required S25 to be destacked for the final time on November 16, and restacked on November 17.^[62] The following day, November 18, Booster 9 and Ship 25 lifted off with all 33 engines lit at 7:02 am CST.^[65] Following the successful separation from S25, B9 was destroyed after several engine failures during the boost-back burn.^[65]

B10 was fully stacked in March 2023.^[66] B10 was moved to Massey's for cryogenic testing on July 7, undergoing a cryogenic proof test on July 18.^[66] It was moved to production site on July 21, and on September 10, B10 was moved back to Massey's for additional cryogenic testing.^[66] Three cryogenic tests were performed on September 13, September 15, and September 17.^[66] It was moved back to Mega Bay 1 on September 19 for engine and interstage installation.^[66] On December 4, B10 received its vented interstage,^[66] and was moved to the Rocket Garden on December 5.^[66] SpaceX confirmed that B10 would be used for IFT-3 shortly after that.^[67] On December 18, B10 was moved to the orbital launch site,^[66] followed by a lift onto OLM A the next day.^[66] It aborted a static fire test on December 21, only to conduct a 33-engine static fire test on December 29, followed by its removal from OLM A on December 30.^[66] On January 2, 2024, B10 was moved back to the Production Site,^[66] and was transported to the Orbital Launch Site for a WDR.^[66] On February 9, B10 was lifted onto OLM A,^[66] and on February 10, Ship 28 (S28) was lifted onto B10.^[66] S28 was destacked on February 12,^[66] potentially due to an issue with the Vented Interstage.^[66] On February 13, S28 was restacked onto B10,^[66] followed by two aborted WDR attempts.^[66] On February 18, S28 was destacked,^[66] followed by B10s removal from OLM A on February 19.^[66] On February 20, B10 was moved into the Mega Bay,^[66] only to be returned to OLM A on February 28^[66] S28 was stacked on B10 on March 1,^[66] with B10 and S28 completing a WDR on March 3.^[66] The vehicles were destacked for FTS arming on March 5,^[66] which occurred on March 8,^[66] followed by S28 being restacked on March 10.^[66] On March 14, B10 was launched with S28 on IFT-3, completing the ascent burn with zero engine failures. Six engines failed during the boostback burn.^[68] During its landing burn, only three engines started up with two failing shortly thereafter.^[69]

In June 2023, B11 was fully stacked.^[70] On October 12, B11 was moved to Massey's test site on a Thrust Simulator Stand, where it was cryo-tested two days later.^[71] It was then tested on October 18. On November 19, B11 was moved back to Mega Bay 1 for engine and interstage installation.^[71] On February 2, 2024, SpaceX released an image of B11, with multiples engines being visible.^[72] It was moved to the Launch Site for static-fire testing on April 4^[73] before being lifted onto OLM A.^[71] It conducted a 33-engine static-fire on April 5.^[74] On April 7, it was removed from OLM A,^[71][75] and rolled back to Mega Bay 1 for pre-flight modifications.^[71][75] On April 28, B11's Vented Interstage was rolled into Mega Bay 1.^[71] B11's vented interstage was installed between April 28 and May 7.^[71] On May 10, B11 was rolled out of Mega Bay 1,^[71] and rolled to the Orbital Launch Site.^[76] It was lifted onto the OLM on May 11.^[77] On May 15, Ship 29 (S29) was lifted onto B11 for Wet Dress Rehearsal testing,^[78] with the combined vehicle completing a partial cryogenic test on May 16.^[79] A full Wet Dress Rehearsal was conducted on May 20,^[80] followed by S29 being destacked for tile work on May 21.^[71] S29 was restacked on May 26,^[71] followed by a second Wet Dress Rehearsal on May 28.^[81] On May 29, S29 was destacked for final tile work and Flight Termination System (FTS) Installation,^[71] with FTS installation occurring on May 30.^[71] S29 was restacked on June 1,^[71] followed by a third destack on June 4.^[71] S29 was stacked onto B11 for the fourth and final time on June 5.^[71] On June 6, B11 and S29 launched on IFT-4, with a single engine failure occurring shortly after liftoff.^[82] The boostback burn saw no engine failures, though a second engine failed during the landing burn.^[82] B11 was destroyed after tipping over, with diving vessels being observed with debris at its landing site in mid September.^[83] Musk confirmed this on September 22, showing an image of B11's aft section, missing several engine and the aft dome.^[84][85] On October 9, Vice President of Build and Flight Reliability of SpaceX Bill Gerstenmaier claimed that B11 landed within "half a centimeter" of the target.^[86]

B12 began assembly in June 2023.^[70] On December 28, 2023, B12 was moved to Massey's for cryogenic testing.^[87] On January 10, 2024, B12 underwent its first cryogenic test,^[87] and a second test on January 12, 2024.^[87] B12 was moved to the rocket garden in mid-January 2024,^[88] and on January 24, 2024, B12 was moved into Mega Bay 1 for engine installation.^[89] On February 2, 2024, SpaceX released an image showing the process of engine installation on B12 had begun.^[72] B12 rolled out to the launch site on July 9 for static fire testing,^[90] followed by a lift onto OLM A the same day.^[91] On July 11, B12 underwent a pressurization test.^[87] On July 12, B12 conducted a 33 engine spin prime,^[92] followed by a 33 engine static fire on July 15.^[93] B12 was rolled back for vented interstage installation on July 16, 2024.^[94] On July 29, B12s vented interstage was seen entering Mega Bay 1, presumably for integration with the booster.^[95] SpaceX claimed that B12 and S30 were ready to fly on August 8.^[96] On September 20, B12 was rolled to the launch site alongside its vented interstage,^[97] where it was lifted above OLM A in order to simulate the return of the booster to the OLM after the catch.^[87] It was then lowered onto OLM A,^[87] followed by integration with its vented interstage.^[87] On September 21, S30 was lifted onto B12.^[98] A partial wet dress rehearsal was conducted on September 23.^[99] On September 30, S30 was removed from B12,^[100] followed by the vented interstage.^[100] The vented interstage was lifted back onto B12 on October 4.^[101] S30 was restacked onto B12 on October 5.^[102] A second partial wet dress rehearsal occurred on October 7.^[103] On October 8, S30 was destacked for FTS installation ahead of flight.^[104] FTS was installed on both vehicles on October 9.^[105] S30 was stacked onto B12 for Flight 5 on October 11.^[87] B12 and S30 launched on October 13, with B12 successfully conducting the ascent, boostback, and landing burns with zero engine failures, before being caught by the chopsticks.^[106] B12 was then lowered onto OLM A.^[107] Musk claimed that B12 suffered damage that could be "easily addressed", including warping of the outer engine nozzles.^[108] B12's FTS was removed on October 14,^[109][110] followed by its removal from OLM A on October 15.^[111] It was then rolled back to Mega Bay 1 for post-flight inspections.^[112]

B13's assembly was completed on February 3, 2024.^[113] It was rolled to Massey's test site for cryogenic testing on April 25.^[114] B13 completed its first cryo-test on April 26,^[115] and a second cryogenic test on April 29.^[116] It was then moved to Mega Bay 1 on May 3.^[117]

On May 11, 2024, SpaceX released an image showing that B14 had been assembled.^[118] B14 was rolled out of Mega Bay 1 on October 2, ahead of a rollout to Massey's the next day.^[119] On October 4, B14 conducted its first cyrogenic test,^[120] followed by a second on October 5.^[121] It was then moved to Mega Bay 1 on October 7.^[122]

On July 23, 2024, B15's aft section was spotted, featuring pressurization tanks for the LOX landing tank.^[123]

On October 14, 2024, the first section for B16 was spotted being moved around Starfactory.^[124] DIVIDE BETWEEN SUPER HEAVY AND STARSHIP

Videos of Starship flight tests
From SpaceX
Starhopper 150m hop
SN5 150m hop
SN6 150m hop
SN8 12.5km test flight
SN9 10km test flight
SN10 10km test flight
SN11 10km test flight
SN15 10km test flight
S24/B7 integrated test flight
S25/B9 integrated test flight
S28/B10 integrated test flight
S29/B11 integrated test flight
S30/B12 integrated test flight

Starship's development is iterative and incremental, using frequent—and often destructive—tests on a series of rocket prototypes.^{[125][126][127]}

SpaceX prototypes are subjected to several tests before they can be launched. Pressure tests come first, during which the tanks are filled with a liquid or gas to test their strength and safety factor. SpaceX tests some tanks beyond the specified limit, to find the point at which they burst. After engine installation, vehicles undergo static fire testing, during which the engines fire while the vehicle is prevented from lifting off. After passing these tests, a prototype vehicle will launch, either flying within the atmosphere, or attempting to reach orbit.^{[128]: 15–19}

Starhopper in March 2019

Starhopper configuration as flown in August 2019

Construction on the initial steel test article—Starship Hopper,^[196] Hopper, Hoppy, or Starhopper^[197]—began at Boca Chica in 2018. Starhopper had a single engine and was test flown to develop landing and low-altitude/low-velocity control algorithms.

Starhopper used liquid oxygen (LOX) and liquid methane fuel. After it completed its testing campaign Starhopper was repurposed as a water tank, weather station and equipment mount for cameras, lights, loudspeakers and a radar system.^[198]

It passed tanking tests, wet dress rehearsals, and pre-burner tests.^[199] A storm blew over and damaged Starhopper's nose cone. SpaceX continued testing without one.^[199]

It then passed a static fire test,^[200] and in a tethered test reached 1 meter altitude.^{[201][202][199]} On July 25, 2019, a Starhopper test flight reached about 20 m (66 ft) altitude,^[203] followed by an August 27 test that rose to 150 m (490 ft)^[204] and landed about 100 m (330 ft) from the launchpad, the Raptor's first use in flight.

On September 3, 2024, Starhopper was moved to a parking lot nearby the launch site.^[205]

SpaceX began building the high-altitude prototype, Mk1 in Texas and Mk2 in Florida, using competing teams that shared progress, insights, and build techniques.^[206][201] The vehicle featured three Raptor methalox engines and were meant to reach an altitude 5 km (3.1 mi).^[207][208]

Mk1 was 9 m (30 ft) in diameter and about 50 m (160 ft) tall,^[209] with an empty mass of 200 t (440,000 lb). It was intended for testing flight and reentry profiles, in pursuit of a suborbital flight. When announced, it had three sea-level Raptors, two fins each at the front and back, and a nose cone containing cold-gas reaction control thrusters, with all but the aft fins being removed afterwards.^{[210][211][212]}

On November 20, 2019, Mk1 blew apart during a pressure test.^[213][214]

SpaceX began Mk2 in Florida, sharing progress, insights, and build techniques with the Mk1 team in Texas.^[206][201] It was never completed.^{[138][139][215]}

The Mk3 prototype began construction in late 2019.^[209] In December 2019, Musk redesignated Mk3 as Starship SN1, and predicted that minor design improvements would continue through SN20.^[216] SpaceX began stacking SN1 in February 2020 after successful pressurization tests on propellant tank prototypes. SN1 was destroyed during a cryogenic pressurization test on February 28, 2020, due to a design flaw in the lower tank thrust structure.^[217][218]

Mk4 began construction in Florida in October 2019,^[219] but was scrapped after a few weeks.^[138]

SN3 was destroyed during testing on April 3, 2020^[145][144] due to a failure in the testing configuration.^[128]

SN4 passed cryogenic pressure testing on April 26^[220] and two static fires on May 5 and May 7: one tested the main tanks, while the other tested the fuel header tank.^[221] After uninstalling the engine, a new cryogenic pressure test was conducted on May 19. A leak in the methane fuel piping ignited, causing significant damage to the rocket's base, destroying the control wiring.^[222] SN4 was destroyed on May 29, due to a failure with the Ground Support Equipment's quick-disconnect function.^[223]

After a static fire test on July 30,^[224] SN5 completed a 150-meter flight (August 4) with engine SN27.^[150][225] SN5 was scrapped in February 2021.^[226]

SN6 completed a static fire on August 24, and a 150-meter hop test flight with engine SN29 on September 3. In January 2021, SN6 was scrapped.^[227]

SN8 was planned to be built out of 304L stainless steel,^[228] although some parts may have used 301L steel.^[229] In late October and November, SN8 underwent four static fires. During the third test, on November 12, 2020, debris from the pad caused the vehicle to lose pneumatics.^[230] Launch took place on December 9. Launch, ascent, reorientation, and controlled descent were successful, but low pressure in the methane header tank^[231] kept the engines from producing enough thrust for the landing burn, destroying SN8 on impact.^[232]

On December 11, the stand beneath SN9 failed, causing the vehicle to tip and contact the walls inside the High Bay.^[233] SN9 then required a replacement forward flap.^[234] SN9 conducted 6 static fires in January 2021,^[158] including three static fires in one day.^[235] After these tests, two engines had to be replaced.^[236] After struggling to gain FAA permission,^[237] SN9 conducted a 10 km (6.2 mi) flight test on February 2. Ascent, engine cutoffs, reorientation and controlled descent were stable, but one engine's oxygen pre-burner failed, sending SN9 crashing into the landing pad.^[238] The landing pad was then reinforced with an additional layer of concrete.^[239] After the SN9 failure, all three engines were used to perform the belly flop landing sequence. This offered a failsafe should one fail to ignite.^[240][166]

SN10 underwent a cryogenic proof test on February 8, followed by a static fire on February 23.^[160] After an engine swap, another static fire was conducted on February 25.^[241]

Two launch attempts were conducted on March 3. The first attempt was automatically aborted after one engine produced too much thrust while throttling up. After a 3-hour delay to increase the tolerance,^[242] the second attempt launched and landed successfully. The test ended with a hard landing-at 10 m/s – most likely due to partial helium ingestion from the fuel header tank. Three landing legs were not locked in place, producing a slight lean after landing. Although the vehicle initially remained intact, the impact crushed the legs and part of the leg skirt. Eight minutes later the prototype exploded.^[243][244]

SN11 accomplished a cryogenic proof test on March 12 that included a test of the Reaction control system (RCS),^[245][246] followed by a static fire test on March 15, 2021. Immediately after ignition, the test was aborted.^[247] Another static fire attempt^[248] led to reports that one of the three engines had been removed for repairs.^[249] A replacement engine was installed^[250] and a third static fire was attempted on March 26.^[251] A 10 km flight test was conducted in heavy fog on March 30. The test included engine cutoffs, flip maneuver, flap control and descent, along with a visible fire on engine 2^[252] during the ascent. Just after the defective engine was re-ignited for the landing burn, SN11 lost telemetry at T+ 5:49 and disintegrated.^[253]

SN12 through SN14 never launched.^[254]

SN15 introduced improved avionics software, an updated aft skirt propellant architecture, and a new Raptor design and configuration.^[255][256] A Starlink antenna on the side of the vehicle was another new feature.^[257] SN15 underwent an ambient temperature pressure test on April 9, 2021,^[258] followed by a cryogenic proof test on April 12, and a header tank cryogenic proof test on April 13.^[259][260] A static fire was conducted on April 26,^[172][173] and a header tank static fire on April 27 followed.^[261] A 10 km (33,000 ft) high-altitude flight test was conducted in overcast weather on May 5, achieving a soft touchdown. A small fire near the base started shortly after landing, though this was extinguished.^[262] After its engines were removed, it was moved to the Rocket Garden on May 31.^[263] On July 26, 2023, SN15 was scrapped.^[264]

SN16 was scrapped, while SN17, SN18, and SN19 were never completed.

SN20 was the first vehicle with a complete thermal protection system (TPS). SN20 rolled out to the launch mount on August 5, 2021, and was stacked onto Booster 4 for a fit test.^{[181][265][266]} FCC filings in May 2021 by SpaceX stated that the orbital flight would launch from Boca Chica. After separation, Starship would enter orbit and around 90 minutes later attempt a soft ocean landing around 100 km off the coast of Kauai, Hawaii.^[267] However, S20 was retired in March 2022. As of April 2024, SN20 (Ship 20) remains in the Rocket Garden.

Ship 21 was scrapped before being completed.^[268]

Ship 22 moved to the Rocket Garden in late February 2022. It was later scrapped, in favor of using S24 for IFT-1.^[268]

Ship 23 was scrapped and partially recycled in Ship 24.^[269]

Ship 24 was first spotted in November 2021, and made cryogenic proof tests on June 2, 2022, June 6, 2022, and June 7, 2022.^[270][271] On June 9, 2022, Ship 24 was rolled back to the production site for engine installation.^[272] On July 5, 2022, Ship 24 was rolled back to the launch site and lifted onto Suborbital Pad B a day later.^[273][274] Ship 24 then conducted a successful spin prime test on July 18, 2022.^[275] On July 20, 2022, Ship 24 completed two successful spin prime tests.^[276] On July 21, 2022, Ship 24 again conducted two spin prime tests, the first test use one engine, while the second test involved two engines.^[277] On July 28, 2022, Ship 24 successfully completed a forward flap test.^[278] Ship 24 completed two additional successful spin prime tests on August 8, 2022.^[279] It was static fired with two engines on August 9, 2022.^{[280][281][282]} On August 24, 2022, Ship 24 successfully completed an ignitor test with all 6 of its engines.^[283] On August 25, 2022, Ship 24 went through an additional spin prime test.^[284] On September 8, 2022, Ship 24 underwent a six engine static fire test,^[285][286] which damaged around 30 of its 18,000 ceramic tiles.^[287] The ship was repaired, and was subsequently stacked on top of Booster 7 in mid-October, before being destacked on October 16, 2022,^[288] and restacked on October 20, 2022.^[289] On November 8, 2022, Ship 24 was destacked again for static fire tests.^[290] On December 15, 2022, Ship 24 conducted a single engine static test fire.^[291][292] On January 9, 2023, Ship 24 was stacked on Booster 7,^[293] and then destacked on January 24, 2023.^[294] On January 26, 2023, Ship 24 was rolled back to the production site for final TPS work.^[294] On March 31, 2023, Ship 24 was rolled to the launch site for the final time before launch.^[295] On April 5, 2023, Ship 24 had two lift attempts, the first attempt was aborted, however the second attempt, less than a few hours after the first, was successful.^[296] On April 12, 2023, Ship 24 was destacked for flight termination system (FTS) installation before launch.^[297] On April 15, 2023, Ship 24 was stacked onto Booster 7 for the final time before launch.^[298] On April 20, 2023, it was destroyed in flight along with Booster 7 after spinning out of control.^[299][300]

Ship 25 was a Starship prototype similar to the destroyed Ship 24.^[75] It flew on the second Integrated Flight Test with Booster 9 and was the first Starship to pass the Kármán Line and reach space.^[71] Like Ship 24, Ship 25 featured a heat shield. A payload bay was also built, but was permanently welded shut.^[75] It was used to test the cryogenic test stands at Massey's.^[75] During the third week of May 2023, Ship 25 was moved to the launch site and lifted onto suborbital pad B in preparation for engine testing.^[75] On June 21, 2023, Ship 25 performed a successful spin prime test.^[75] On June 24, 2023, it was announced that Ship 25 would be the first vehicle to use hot-staging (when the second stage fires its engines while some of the booster's engines are still firing).^[75] On June 26, 2023, Ship 25 underwent its first static fire test, igniting all six engines.^[75] On August 5, 2023, it was moved to the Rocket Garden for final TPS work.^[75] On September 5, 2023, it was moved back to the Orbital Launch Site, followed by stacking onto B9.^[75] On September 14, 2023, it was removed from B9.^[75] On September 27, 2023, it was lifted back onto B9, before being destacked on October 5, 2023.^[75] It was then restacked on October 16, 2023, only to be destacked the next day.^[75] This was followed by a restack three days later.^[75] On October 24, B9 and S25 completed a WDR.^[75] On October 26, 2023, S25 was removed from B9.^[75] It was restacked on November 1, 2023,^[75] and then destacked on November 2, 2023,^[75][301] followed by FTS installation on November 9, 2023.^[75] On November 10, 2023, S25 was stacked onto B9,^[75] and then destacked on November 11, 2023.^[75] On November 15, 2023, S25 was stacked onto B9 for the Second Integrated Flight Test.^[302] Due to a failed grid fin actuator on B9, S25 was destacked on November 16, and restacked on November 17.^[75]

On November 18, 2023, Ship 25 was launched atop Booster 9 on the second Integrated Flight Test. Ship 25 successfully separated from Booster 9.^[71] Near the end of its burn, a LOX dump started a fire in the engine bay, causing an explosion.^[71] The autonomous flight termination system activated, destroying the vehicle.^[71]

Ship 26 is an expendable Starship prototype, lacking heat shield tiles and flaps. Ship 26 also lacks a payload bay door. After several cryogenic tests, S26 was moved to the engine installation stand. In December 2023, S26 was moved to the Rocket Garden.^[303] On September 9, 2023, S26 was moved to Suborbital Pad B for static fire testing.^[304] S26 then underwent a cryogenic test on October 9, 2023, followed by a preburner test with a single engine nine days later, a first for vehicles equipped with Raptor 2 engines.^[305] This was followed by a single engine static fire test on October 20, 2023, simulating a deorbit burn.^[187] It was moved back to the Rocket Garden one week later.^[306] On December 7, 2023, S26 was placed on an engine stand, and a crane was attached to S26, potentially indicating an imminent scrapping.^[307] However, on December 11, 2023, the crane was detached from S26, and S26 was returned to the Rocket Garden.^[308] On December 16, 2023, SpaceX crews began welding large steel pieces onto the stack weld connecting S26's payload bay and forward dome sections, likely an attempt to reinforce the payload bay, although it is unclear what the reason behind this reinforcement is.^[309] Additional supports were added on December 20, 2023.^[310] S26 was moved into Mega Bay 2 on May 7, 2024,^[311] and rolled to the Massey's site on May 8 for static fire stand testing.^[312][313] S26 conducted a cryogenic test on May 24,^[314] followed by a six engine^[315] static fire on June 3.^[316] On June 12, S26 was moved to the Rocket Garden,^[317] where it remained until August 13, when it was moved into Mega Bay 2.^[318] S26's engines were removed on August 14,^[319] before being returned to the Rocket Garden.^[320]

Like S26, S27 was an expendable prototype, lacking heat shield tiles. It was the first Ship to have a reinforced payload dispenser. Ship 27 was scrapped on July 20, 2023, after the common dome failed.^[321] S27's aft section was then converted into a test article, presumably to test the engine shielding design present on S25.^[322] On September 27, 2023, S27 was rolled to the Massey's test site.^[322]

Ship 28, along with subsequent Block 1 models, features heat shield tiles as well as reinforced Starlink satellite dispensers.^[323] In July 2023, S28 underwent cryogenic testing, before being moved onto the engine installation stand. On August 18, 2023, S28 began to have its engines installed.^[70] On November 23, 2023, S28 was moved to the High Bay for TPS work.^[70] On December 7, 2023, SpaceX confirmed that S28 would be the next vehicle to fly.^[324] On December 14, 2023, S28 was moved to the launch site^[70] and lifted onto suborbital Pad B for static fire testing.^[70] On December 16, 2023, S28 completed a spin prime test,^[70] followed by a six engine static fire test on December 20, 2023.^[70] This was followed by a deorbit burn test on December 29, 2023.^[70] In early January 2024, S28 was moved back to the production site.^[70] On January 25, S28 was briefly removed from the High Bay, before returning after realignment of its SPMTs.^[70] On January 27, 2024, S28 was moved to the Sanchez site, where it was lifted onto the Engine Installation Stand.^[70] There, at least one engine was replaced on January 31, 2024.^[70]

S28 was moved to the Orbital Launch Site for IFT-3 on February 10, 2024,^[70] and was stacked onto B10.^[70] S28 was then destacked on February 12, 2024,^[70] potentially due to an issue with the Vented Interstage.^[70] On February 13, 2024, S28 was restacked onto B10.^[70][325] On February 14, 2024, a Wet Dress Rehearsal (WDR) attempt was aborted.^[70] A second WDR was attempted on February 16, 2024, and it was also aborted.^[326] On February 18, 2024, S28 was destacked,^[70] and on February 19, it was lifted onto Suborbital Pad B.^[70] It underwent a spin prime test on February 26, 2024,^[70] before being removed from Suborbital Pad B on February 28, 2024.^[70] S28 was stacked on B10 on March 1, 2024.^[70] On March 3, 2024, B10 and S28 completed a WDR.^[70] On March 5, 2024, S28 was destacked for FTS arming.^[70] The FTS was armed on March 8, 2024,^[70] followed by S28 being restacked on March 10, 2024.^[70] S28 flew with B10 on March 14, 2024, and reached orbit. It conducted tests of the Payload Dispenser and fuel transfer system, before being destroyed during reentry.^[327]

On September 22, 2023, S29 was moved to Massey's for cryogenic testing, where it was cryogenically tested on September 26, 2023.^[72] On October 13, 2023, S29 was temporarily moved to the Rocket Garden. On November 21, 2023, S29 was moved into the High Bay.^[72] In late December, 2023, S29 was moved into Mega Bay 2.^[72] It was returned to the High Bay in late February 2024.^[328] On February 29, S29 was moved to the launch site,^[72] and was lifted onto Pad B on March 2, 2024.^[72] S29 underwent a cryogenic test on March 7, 2024,^[329] followed by a spin prime test on March 11, 2024.^[330] On March 12, 2024, S29 was removed from Suborbital Pad B,^[331] followed by a rollback to the production site.^[72] On March 22, 2024, it was moved back to the launch site, before being lifted onto Suborbital Pad B for static fire testing.^[72] On March 25, 2024, Ship 29 conducted a six engine static fire test.^[332] A single engine static fire test was conducted on March 27, 2024.^[72] On March 28, it was removed from Pad B,^[72] before being returned to the High Bay for Pre-flight modifications.^[72] S29 was moved into Mega Bay 2 on May 10.^[72]

On May 11, S29 was moved to the Orbital Launch Site for IFT-4.^[333] It was lifted onto B11 on May 15,^[334] with the combined vehicle completing a partial Wet Dress Rehearsal on May 16.^[335] A full Wet Dress Rehearsal was conducted on May 20,^[336] followed by S29 being destacked for additional tile work on May 21.^[337] It was restacked on May 26,^[72] followed by a second Wet Dress Rehearsal on May 28.^[338] Ship 29 was destacked on May 29 for final tile work and Flight Termination System (FTS) installation,^[72] with FTS installation occurring on May 30.^[72] S29 was restacked on June 1,^[72] followed by a third destack on June 4.^[72] S29 was stacked onto B11 for the fourth and final time on June 5.^[72] On June 6, S29 was launched with B11 on IFT-4, with S29 completing a full ascent burn with no engine failures.^[65] It retained attitude control into reentry, despite the near-complete loss of a forward flap,^[65] and achieved a successful landing burn.^[65] As of June 8, S29 is the largest artificial object to reenter Earth's atmosphere.^[339]

S30 was moved to Massey's for cryogenic testing on December 30, 2023.^[340] On January 3, 2024, S30 underwent its first cryogenic test.^[341] On January 10, S30 was returned to the High Bay.^[342] It was moved into Mega Bay 2 on April 4, 2024, before being lifted onto Engine Installation Stand 2.^[343] The engines were installed between April 8 and April 9, 2024.^[343] On May 1, 2024, it was rolled to the Suborbital Launch Site,^[344] where it was lifted onto Suborbital Pad B for static fire testing.^[345] It conducted a cryogenic test on May 7,^[311] followed by an aborted static fire test.^[346] On May 8, it completed a 6 engine static fire test,^[191] which was also the last static fire to be conducted at the Suborbital Launch Site.^[312] It was removed from Pad B on May 10,^[343] before being rolled to the production site.^[343] S30 was moved into the High Bay on May 11.^[347] On June 5, at least one RVAC was replaced for unknown reasons.^[343] On June 9, Musk claimed that SpaceX would be replacing S30's entire heat shield as a result of data gathered from IFT-4,^[343] with an ablative heat shield underneath for secondary protection.^[348] The removal and replacement of Thermal Protection System tiles began on June 11.^[343] On July 20, S30 was moved into Mega Bay 2 and lifted onto the static fire stand ahead of a rollout to Massey's.^[343] It conducted a 6 engine static fire on July 26,^[349] and rolled back to the production site on July 27.^[343] One of S30's Raptor Vacuum engines was replaced on August 3.^[343] On August 6, S30 was rolled back to Massey's for additional engine testing.^[343] It conducted a spin prime on August 7.^[350] SpaceX claimed that B12 and S30 were ready to fly on August 8.^[350] S30 was then rolled back to the production site.^[343] On September 20, S30 was rolled to the launch site.^[351] A partial wet dress rehearsal was conducted on September 23.^[352] On September 30, S30 was removed from B12,^[100] and restacked onto B12 on October 5.^[353] A second partial wet dress rehearsal occurred on October 7.^[354] On October 8, S30 was destacked for FTS installation ahead of flight.^[355] FTS was installed on both vehicles on October 9.^[356] S30 was stacked onto B12 for Flight 5 on October 11.^[343] On October 13, S30 launched on B12, and reached orbit after a nominal ascent burn with no engine failures. Like S29, S30 retained attitude control through reentry, and successfully reignited its engines for a splashdown in the Indian Ocean.^[357]

On December 14, 2023, S31 was moved to the Rocket Garden,^[358] before being moved back into the High Bay on January 4.^[359] It was rolled to Massey's for cryogenic testing on May 11.^[360] On May 12, S31 conducted a cryogenic test, ending prematurely due to an electrical anomaly.^[361] It was rolled back to the production site for repairs on May 15. On July 1, it returned to Massey's for cryogenic testing.^[362] It was cryogenic tested on July 2 and July 3.^[363] On July 5, S31 was moved to Mega Bay 2 for engine installation.^[364] Engine installation began on July 22.^[365] On July 25, S31 was rolled into the High Bay for additional work.^[366] The process of replacing S31's thermal protection system began in early august.^[367] On September 6, S31 was rolled to Massey's for static fire testing.^[368] It attempted to static fire on September 8, with the test being aborted due to the weather.^[369] S31 conducted a static fire on September 18, 2024.^[66] On September 20, S31 was rolled back to the production site.^[370]

On November 24, Elon Musk implied that S32 would be the last Block 1 starship.^[371] On January 10, 2024, S32 was moved to the Rocket Garden.^[340] FCC filings confirmed on June 21 indicated that Flight 7 would use a Block 2 vehicle, implying that S32 would not be used on a flight.^[372]

In late November, 2023, the original S33's components were scrapped,^[373] alongside the components of the original S34 through S38.^[374]

Block 2 ships will feature a new forward flap design, increased propellant capacity, and an increase in thrust.^[375] Additionally, the leeward side of the vehicle has some external stringers.^[376] These vehicles will be a total of 1.8 m (5 ft 11 in) meters taller than the previous Block 1 ships.^[375]

On July 24, 2024, S33's nosecone and payload bay were rolled into Mega Bay 2.^[377] Stacking of the vehicle was completed on August 23.^[378]

On September 19, 2024, S34's nosecone was rolled into the High bay ahead of integration with the payload bay.^[379] The combined assembly was then rolled into the Starfactory,^[380] and from there into Mega Bay 2.^[381]