SpaceX Starship thermal tile problems cast doubt on rapid reusability

Experts warn that SpaceX's Starship faces serious challenges with its ceramic thermal protection tiles. The tiles expand differently from the hull, are vulnerable to vibration and impact, and can crack or let plasma through, raising concerns that the vehicle may not achieve the fast turnaround Musk envisions and could incur higher refurbishment costs.

Meanwhile, Boeing is preparing its CST‑100 Starliner for a return to flight after a series of technical failures on its first crewed mission. Modifications such as thermal shunts and added insulation are being tested, and NASA expects an uncrewed launch to the International Space Station no earlier than the fourth quarter of 2026.