SpaceX just announced New COPV Change after Starship S36 Sabotaged: Ship 36 was completely destroyed in a catastrophic explosion at the Massey’s Test Site. The cause? A COPV — a Composite Overwrapped Pressure Vessel — once considered highly reliable. But no detailed explanation has been released. Now, a credible insider suggests the failure wasn’t just an accident… could it have been sabotage?
This lines up with whispers circulating in the space community, but what really happened—and what can be done to prevent another COPV disaster? Let’s explore in this four-part breakdown:
- What exactly went wrong with the COPV
- Why sabotage is being discussed
- What SpaceX must do to prevent repeats
- How far Starship’s recovery might go
First, a quick update…
Good News: Axiom 4 Launches Successfully
At 2:30 a.m. on June 25th, SpaceX and NASA launched Axiom 4 aboard Crew Dragon. This was much more than a crew flight—it carried four international astronauts and 60 scientific experiments from 31 nations, exploring areas like muscle deterioration, cardiovascular health, and the immune system in microgravity.
A major win for both science and the Crew Dragon program. The spacecraft is set to dock this Thursday at 7:00 a.m., while SpaceX teams return to work addressing the disaster at Massey’s.
COPV Failure: What Actually Happened at Massey’s
Visuals from Ship 36’s wreckage show total destruction. Cleanup could take a month, but the root cause is clear: a nitrogen‑COPV in the nose cone failed, triggering a massive explosion wired.com+15reuters.com+15nasaspaceflight.com+15reuters.com+2spacenews.com+2space.com+2.
COPVs are lightweight, high‑pressure tanks used to store gases—much lighter than metal tanks. In Starship, they help pressurize fuel systems for the Raptor engines. Problems occurred when:
- A COPV likely ruptured below proof pressure, punching through the ship’s skin
- This damaged fuel lines and the forward dome, causing propellant leaks
- These leaks ignited, triggering a rapid unscheduled disassembly (RUD) in two stages reuters.com+6nasaspaceflight.com+6reddit.com+6
Musk noted that this design failure had never occurred before, calling it “the first time ever for this design” space.com+4reuters.com+4wired.com+4.
This follows previous COPV‑related incidents: the CRS‑7 failure in 2015 and the AMOS‑6 explosion in 2016 reuters.com+15en.wikipedia.org+15wired.com+15.
Sabotage Claims: What We Know and What We Don’t
🚨 A SpaceX insider on X (Twitter) alleged that inexperienced local hires, part of the so‑called “tent‑era crew”, mishandled COPVs—banging them during installation and violating protocols. This person, one of only two certified COPV inspectors on site, was denied access after raising concerns .
He has military and aerospace credentials, yet saw procedures flouted. Whether this rises to malicious sabotage or just gross negligence is still unconfirmed.
Musk has previously said sabotage is “unlikely, but a real possibility”, based on past comments wired.com+2space.com+2spacenews.com+2. But without clear proof—or a public investigation—these remain rumors.
COPV Basics: Types, Risks, and What Went Wrong
How COPVs Work
COPVs are composite tanks wrapped in carbon fiber over a metal liner. They’re lightweight and strong, but susceptible to flaws in wrapping or liner buckles, which can trap dangerous gases en.wikipedia.org+9thehindu.com+9reddit.com+9thetimes.co.uk+15en.wikipedia.org+15vice.com+15.
Type 3 COPVs, used in Starship, are aluminum‑lined and standard. SpaceX may now need to consider upgrading to Type 5—lighter, liner‑free, but still maturing for commercial use .
Known Failure Mechanisms
- Buckling in the aluminum liner, creating pockets of liquid or solid oxygen
- This leads to friction or fiber rupture in the overwrap—igniting inside the tank electronics360.globalspec.comvaluewalk.com+5vice.com+5en.wikipedia.org+5
- Cryogenic conditions worsen the problem by creating solid oxygen that gets stuck in folds wired.com
SpaceX’s long‑term plan: use warmer helium, slower loading, and redesign COPVs to prevent buckles nasaspaceflight.com+3valuewalk.com+3electronics360.globalspec.com+3.
Preventing Future COPV Failures: Steps SpaceX Must Take
Enhanced Testing and Inspection
- Standalone testing under cryogenic, vibration, and operational loads
- Use non-destructive evaluation: ultrasonics, X‑ray radiography, eddy current analysis nasaspaceflight.com
- Employ crack-growth prediction software like NASG O based on fracture mechanics
Procedural Overhaul
- Reinforce handling protocols, especially on-site
- Retrain all workers, not just certified inspectors
- Empower inspectors to halt assembly if integrity is in doubt
Material and Design Upgrades
- Migrate to Type 5 COPVs once certified
- Redesign existing Type 3 vessels to eliminate buckling zones
- Improve pressure cycling procedures and helium loading standards
Starship’s Resilience: Damage Done and Recovery Today
Ship 36’s explosion heavily damaged the Massey’s static fire stand and pipelines to the fuel farm reddit.com+1reddit.com+1thehindu.com+15nasaspaceflight.com+15wired.com+15. However:
- Past recoveries (e.g., launch mount rebuild) took only three months
- SpaceX’s dramatic recovery record suggests Massey’s will be back online soon
- Ship 37 and 38 are being prepped, though static‑fire may be paused pending infrastructure repair
Musk still targets Mars transfer windows—perhaps even in the 2026–27 range—but puts realistic odds at 50/50 .
Conclusion: Sabotage or Structural Weakness?
The COPV failure on Ship 36 is a wake‑up call. While procedural lapses and material flaws likely contributed, sabotage—though still unverified—should be considered and investigated.
SpaceX’s recovery depends on:
- Implementing new COPV designs (Type 5, scratch‑proof lining)
- Procedural and inspection protocol upgrades
- Infrastructure repairs and successful test restarts
Their track record of resilience is unmatched, but internal discipline and quality control must rise to meet their ambitious Mars timeline.
FAQ: Understanding the COPV Explosion
- What caused the Ship 36 explosion?
A nitrogen COPV in the nose broke, rupturing other systems and igniting propellant electronics360.globalspec.comreddit.comwired.com+4reuters.com+4en.wikipedia.org+4. - Is sabotage proven?
Not confirmed. Claims from an insider suggest mishandling, but SpaceX hasn’t verified sabotage. - What is a COPV?
A lightweight high-pressure tank made from an aluminum liner wrapped in carbon-fiber composite valuewalk.com. - Why are COPVs risky?
Liner buckles can trap oxygen, which can ignite under pressure, causing tank failure wired.com. - Has SpaceX had COPV failures before?
Yes—Falcon 9’s CRS‑7 in 2015 and AMOS‑6 in 2016 reddit.com+5en.wikipedia.org+5wired.com+5. - What changes are being made?
Warmer helium loading, redesigns to prevent buckles, and new inspection protocols reddit.com+4valuewalk.com+4wired.com+4. - Could Type 5 COPVs fix it?
Possibly. They’re lighter and more robust, but need further testing and cost optimization . - How fast can Starship recover?
Depending on repair scope, similar recoveries have taken as little as three months. - Will this delay Mars plans?
A bit—Musk admits the odds are about 50/50; delays are likely, but not mission abandonment. - Are people safe?
Yes—all personnel were cleared from the area well before the explosion space.comhoustonchronicle.comreuters.com+3theverge.com+3indiatoday.in+3. - Will Falcon 9 be affected?
No. Starship’s COPVs differ entirely from Falcon’s nasaspaceflight.com. - What about environmental impact?
Debris cleanup across private land and even Mexico is in progress reuters.com. - Is the FAA involved?
Not for this event—it was ground-based. It was a SpaceX-only investigation nasaspaceflight.com+1reddit.com+1. - What inspection methods can prevent this?
Enhanced ultrasonics, X-ray, eddy current, and fracture-prediction software reddit.com. - Will SpaceX ever use non-metal COPVs?
It’s on the roadmap. Type 5 COPVs could be deployed in future Starship designs space.com+15en.wikipedia.org+15indiatoday.in+15space.com+11nasaspaceflight.com+11reuters.com+11.
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