To summarize, you are assuming that SpaceX is making mistakes that any mechanical engineering student would be able to avoid, and is also not doing any stress simulation in CAD. Given the performance of SpaceX products in the past in this regard (0 structural failures in their launch history), do you think that assumption is warranted?
Some posts with photo(s) in this topic about Starship in the recent past:
- implosion of a pipe running inside one of the propellant tanks, apparently wall thickness was calculated to thin,
- destruction of the concrete under the launch table with debris flying miles away,
- a photo placed by Michel Van showing that the Starship rocket was bent before attempting stage separation, which did not succeed.
In the mean time more than 1000 changes have been made to Starship rocket, including reinforcements that need not have been necessary if the original design calculations had been correct.
Pardon me if I assume that SpaceX engineers can make mistakes.
Musk is known to have said:
If things are not failing, you are not innovating enough.
I don't agree with that. All failures are due to mistakes in design and engineering, not due to lack of innovation.
SpaceX seems to do things mainly by
trial and error, without much thought in advance.
Of course one learns from ones mistakes, but that does not mean that one could learn as much as possible by making as many as possible mistakes.
SpaceX can work like that at a remote location in a state like Texas. The rest of the industry however can't get away with that way of working. Imagine Boeing building and testing planes like SpaceX has been doing the past 20 years. Or companies building refineries, chemical plants, nuclear power plants, skyscrapers, .......
Musk is also known for saying:
The best part is no part.
I agree with that. However I estimate that the vented interstage consists of 300 or more separate pieces of metal (depending on how much pieces are used in the construction of the inner ring), held together by some 9000 spotwelds and other welds. That's without counting the heat shield.
It's a mystery how this ever got Musk's approval.