Earlier quoted context omitted.
> So yes it seems reasonable to me that these are groundbreaking challenges. Isn't weld strength something engineers would know/understand in advance, though? How would it come as a surprise that the welds would fail under pressure? It seems strange to me that Musk could be spending so much time working on Starship, and somehow a "badly designed, badly built, and badly checked" rocket makes it to the platform and exp…
Welding by hand is both an art and a science. There is going to be variability in the quality of the weld, which will introduce variability into the strength. Machines can be far more precise and consistent compared to humans. They probably designed their tolerances assuming perfect welds and then didn't have them.
This sounds like terrible engineering practice.