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SpaceX is building Starship’s first orbital-class booster at a breakneck pace

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Within the last week, SpaceX’s South Texas Starship factory appears to have kicked things into high gear and are now assembling the first orbital-class Super Heavy booster prototype at a breakneck pace.

While the assembly of the Super Heavy known as Booster 4 (B4) wasn’t too dissimilar to what CEO Elon Musk described as a “very hard” build of Booster 3 up to last week, work on the rocket has visibly accelerated. Since January 2020, the process of building Starships and Super Heavy boosters has been fairly simple. Both onsite and offsite, raw materials (mostly sheet steel) are cut, bent, and welded into relatively small parts that then make their way to (or around) Boca Chica by truck, forklift, or crane.

With the help of jigs and good amount of automation, the resulting hardware is then welded together to form domes, header tanks, transfer tubes, tank barrels, flaps, and more. Once subassembly is complete, those integrated rocket sections are reinforced with stringers, ribs, and baffles and outfitted with mechanisms, hardpoints, brackets, plumbing, and more. Finally, final assembly – better known as stacking and by far the most visible step – can begin and technicians stack each of those premade segments on top of each other to form a complete Starship or Super Heavy.

While part fabrication and subassembly integration take weeks or months on their own, those earlier steps can be done concurrently, meaning that SpaceX can prepare sections for several different ships and boosters at the same time. For the last six or so months, at any given moment, SpaceX has had 40-60+ rings in work as part of 15-20+ different ring ‘sections’ visible all across Starbase.

Respectively, each Starship and Super Heavy booster require 20 and 36 rings apiece, while each of the propellant storage tanks SpaceX itself is building for the rocket’s first orbital launch pad require 12-15. All told, SpaceX usually has a combination of around 3-5 ships, boosters, and GSE tanks in some stage of assembly. Unsurprisingly, some assembly tasks are harder than others and building the first in a series of prototypes has almost invariably taken far longer than building those that follow.

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Booster 3Booster 4
LOx tank startMay 20thJuly 16th
LOx tank finishJune 18thJuly 30th
CH4 tank startJune 24thJuly 28th
CH4 tank finishJune 27thJuly 29th
Final stackJune 29thAug 1st?

In that sense, it’s not a huge surprise that SpaceX’s Booster 4 assembly has quickly surpassed the pace set with Booster 3 less than a month earlier. SpaceX began stacking Super Heavy B3 around May 20th, starting with the rocket’s aft liquid oxygen (LOx) tank. Five separate stacks are required to turn the LOx tank’s 23 steel rings into a single structure – a process that took SpaceX about a month with Booster 3.

Booster 3 methane (CH4) tank assembly began a few days after the LOx tank’s completion but proceeded far more quickly, wrapping up just a few days later. Two days after that, those two tank sections were then mated and welded together to complete Booster 3’s full ~65m (~210 ft) tall airframe.

Now, just four weeks after Booster 3 was rolled to the launch pad for proof and static fire testing, Super Heavy Booster 4 is well on its way to reaching its full ~65m height almost twice as quickly. With work beginning around July 16th, B4’s oxygen tank is now just missing an (extremely complex) engine section and the booster’s methane tank was stacked to completion – 13 rings tall – in less than two days. That leaves SpaceX’s first potentially flightworthy, orbital-class Super Heavy booster just two stacks away from completion less than two weeks after its assembly began.

If SpaceX can sustain that pace for another few days, Booster 4 assembly will be the fastest of any full-height prototype ever built at Starbase, most of which have been Starship prototypes that are half to about three quarters the size of Super Heavy.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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xAI Colossus pollution concerns in Memphis continue

NAACP & SELC push back against xAI Colossus supercomputer. City tests say air is safe — but activists aren’t convinced.

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xAI-supercomputer-memphis-environment-pushback
(Credit: xAI)

Politicians in Memphis continue to debate about the pollution concerns arising from the xAI Colossus supercomputer.

The NAACP and the Southern Environmental Law Center (SELC) have already expressed interest in filing a lawsuit against xAI over concerns related to air pollution stemming from its gas-powered turbines. Environmental groups have now raised concerns about water pollutants.

On Tuesday, Memphis released third-party air quality test results from June 13 and 16. The tests were conducted in downtown Memphis, Whitehaven, and Boxtown, two miles from xAI’s site. The city claimed levels of 10 pollutants tested were safe.

However, SELC–which is representing the NAACP in a potential lawsuit against xAI–criticized the omission of a key pollutant called ozone from the air quality tests. SELC also noted that monitors were placed against buildings, contrary to EPA guidance, stating air sensors should be “at least six feet above ground level, rooftop, or other objects and away from obstructions, vegetation, or emissions sources that would interfere with the measurement.”

Local opposition intensified, with State Representative Justin J. Pearson asserting: “I stand firm that nothing matters if you cannot breathe clean air, drink clean water, and plant in clean soil.”

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On Wednesday, concerns shifted to the Memphis aquifer, as the Tennessee Department of Environment and Conservation held a virtual meeting on xAI’s wastewater facility.

Activist Pamela Moses criticized xAI. “They are not coming here to uplift or invest in our community. They are here to exploit it. This a distressed and a historically neglected area, and instead of bringing opportunity, Colossal is bringing pollution…secrecy and broken promises,” she said.

xAI’s $80 million Grey Water facility aims to mitigate water concerns. The Colossus Water Recycle Facility, a collaboration between the Tennessee Valley Authority and Nucor Steel, aims to alleviate the strain on the aquifer.

“This project is a game changer in terms of it saving about 4.7 billion gallons of water projected, and about 4.7 billion gallons will remain in the aquifer every year,” said Bobby White of the Greater Memphis Chamber.

As xAI’s Memphis supercomputer continues to be the center of debates, the tension between economic benefits and environmental justice remains unresolved. With ongoing scrutiny and potential legal action, xAI’s efforts to address pollution and water concerns will shape its role in Memphis’ future.

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Tesla Robotaxi’s biggest challenge seems to be this one thing

That big bright thing in the sky might be Tesla’s biggest challenge in terms of Robotaxi.

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Credit: Tesla

Tesla Robotaxi launched just a few days ago to a limited number of riders in Austin, Texas, but its biggest challenge seems to be how the automaker will figure out one thing: the Sun.

Among the company’s unique strategies, its emphasis on using cameras for self-driving is perhaps the most interesting. No other company has adopted the same strategy, as others have relied on cameras with either sensors or LiDAR rigs to accomplish their self-driving deployments.

Tesla, on the other hand, has called LiDAR unnecessary. CEO Elon Musk once called it “a fool’s errand,” stating it was not needed to build an effective self-driving fleet of vehicles.

Musk compared cameras to eyes. Humans don’t need sensors or LiDAR to operate vehicles on the road, so why should cars? This brought up some questions, especially regarding sun glare. Musk said that Tesla would use direct photon counting to see directly into brigt sunlight or even in the darkest conditions at night.

His quote during a recent earnings call was:

“Actually, it does not blind the camera. We use an approach which is direct photon count. When you see a processed image, so the image that goes from the sort of photon counter — the silicon photon counter — that then goes through a digital signal processor or image signal processor, that’s normally what happens. And then the image that you see looks all washed out, because if you point the camera at the sun, the post-processing of the photon counting washes things out.”
So far, this strategy has yielded mixed results. We have seen examples of both:

The Good

We’ve had a handful of people state that they have had no issue using the Robotaxi when it is driving into direct sunlight.

There are plenty of examples:

The Bad

The Verdict

This is obviously a weird case, and it seems that this could be one of the challenges Tesla will face with the deployment of Robotaxi.

While it will get figured out, this is something that could ultimately push back Tesla’s goal of having no safety monitor in the vehicles. However, the instance will be learned and used to improve in the future through its Neural Nets.

The first intervention was captured yesterday, requiring the Tesla safety monitor to stop the vehicle manually on the car’s touchscreen.

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Tesla owners take stand as Stockholm insists on blocking FSD tests

Despite the Tesla owners’ efforts, city officials appear unwilling to budge.

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Credit: Tesla China

Tesla owners in Sweden are taking it upon themselves to lobby for the approval of FSD-style tests in the City of Stockholm. The owners’ efforts come amidst city officials’ continued refusal to allow Tesla to test its autonomous driving system in the capital.

In open letters and social media posts, Tesla owners have urged Stockholm to reconsider its stance, pointing to broader support for FSD trials across Europe. But despite their efforts, city officials appear unwilling to budge, reinforcing the capital’s hardline stance on the Elon Musk-led EV maker.

Public support shows brand loyalty

A group of Swedish Tesla owners recently sent an open letter to Stockholm leaders. Among them is Alexander Kristensen, who has written a letter to officials urging them to allow Tesla to test FSD in the region.

“Members of the Traffic Committee are politically appointed by the Stockholm City Council, whose mandate is determined by the popular vote. Your stance—continuing to block a conditional pilot of FSD— is thus a political decision and fully subject to the electorate’s judgment in the next municipal election.

“When the City prevents tests that could validate and refine the technology locally, it is perceived as hampering life-saving innovation,” the Tesla owners wrote.

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The Swedish Transport Administration issued a response, acknowledging the Tesla owners’ feedback. The Transport Administration noted that it could proceed to grant a permit for Tesla to test FSD, but the company would still have to secure approval from local governments where the FSD-style tests will be conducted.

Stockholm remains firm

Despite this, Stockholm doubled down shortly after, stating that Tesla’s FSD software remains prohibited on city roads.

“Thank you for your comments and for taking an interest in traffic issues concerning the City of Stockholm. As previously stated, the City’s assessment of the current application remains unchanged and our position is set out in the opinion,” the City of Stockhom wrote.

In light of the city’s response, some Tesla owners have vowed to campaign against current officials in the next election.

The push for FSD testing comes as Tesla faces ongoing challenges in Sweden, including a labor dispute with unions over collective bargaining agreements. Since late 2023, the conflict has resulted in strikes, blockades, and legal battles, none of which appear close to resolution. Despite regulatory and labor headwinds, Tesla continues to expand in the region, including the recent installation of Superchargers in union-backed areas.

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