SpaceX might one day return a Starship from Mars to Earth, but their plan requires first building a fuel factory, fuel tank farm and launch tower on Mars. As they found out with the first Starship test, a simple launch pad will come apart and damage the engines, They need the tower (at least a short one with no "chopsticks") because they need the quick disconnect so they can continue to fuel until just seconds before lift off. They need the tank farm and fuel factory to feed the quick disconnect. For that kind of power and to keep it working for years, nuclear power is the only option. Solar does not work well on Mars.
This might work, but building all that infrastructure on Mars will take many, many years and you can't use astronauts until you test the system.
Notice that not even SpaceX is suggesting that a manned return will be faster and cheaper.
If SpaceX were to do this, they would have to send a Starship on a one-way mission. Its primary cargo would be the MAV (Mars Accent Vehicle) and Starship would only replace the "sky crane". This might be the "commercial plan: NASA is considering. SpaceX could have a one-way Starship working in the foreseeable future.
Of the two, Sky Crane has worked twice already on Mars while Starship has yet to reach orbit. I can now see why NASA wants to wait before they decide. At Starship still can't reach orbit and do a fuel transfer by 2026, they go with Skycrane. Witch lander they use SkyCrane or Starship I really just a detail, most of the mission remains the same.
Whilst Mars has lower gravity than Earth, there is still a substantial challenge to lift off the surface, its still 3.78m/s and is only part of the equation, although that is significantly more than any body we have lifted off from except the Earth, this is well within the capabilities of Starship.
If we assume a lift off weight of 10t payload, insluding the crew and all their provisions, a Starship would require around 238t of liquid methane and LOX to give it a
Mars Surface to Low Mars Orbit (LMO)
b. Low Mars Orbit to Earth Transfer Orbit
- Δv required: ~1.5 km/s (Assuming an efficient Hohmann transfer trajectory)
Total Δv:
~5.6 km/s
Thus, claims that this is difficult are spurious. If Starship were designed to only be a one way trip, there is no reason for the design being capable of lifting off the planet.
The issue any such mission would have is O2 production for LOX, current prototype systems would take in excess of 10 years to produce the required 184t of Oxygen using even a scaled up MOXIE @ 2kg per hour would take in excess of 10 years - to produce the required 54t of Methane would take around 2 years if you also take into account that for every 100kg of CH4 required, you need to first produce 25kg of H2, which would need to be electrolysed from water.
Of course, an alternative way for the sample return would be for a Starship crew to take a solid propellant rocket with them - it would require to have a lift of weight of around 500kg with a 25kg sample payload, around 1m diamter and 4.5m length.