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SpaceX Starship factory breaks ground on an even bigger ‘high bay’

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4 years ago

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SpaceX appears to have more or less broken ground on a new, even bigger ‘high bay’ assembly facility at its Boca Chica, Texas Starship factory.

Barely one year ago, SpaceX erected the first prefabricated steel sections of what eventually become its Starship factory ‘high bay’ – a spartan 81m (~265 ft) tall designed at the most basic level to shield final Starship and Super Heavy booster assembly from the elements. Situated near the southernmost tip of Texas and just a few miles west of the Gulf of Mexico, those “elements” can be less than pleasant at SpaceX’s primary Starship factory, ranging from sauna-like heat and humidity and mosquitoes the size of quarters to regular downpours, thunderstorms, tropical conditions, and even hurricanes.

While a great deal of work at Starbase is still done out in the open with little more than an umbrella as protection, SpaceX has nevertheless worked to find a middle ground where the most sensitive work (mainly structural welding) can be mostly shielded from wind and rain. First, SpaceX built a (relatively) tiny ‘windbreak’ too small for much of anything. Two years later, the windbreak is partially used for Starship nose section assembly – when a nose cone is stacked on and welded to a separate stack of four steel rings.

A few months after the triangular windbreak was fully finished, SpaceX started work on a larger box-like building that would eventually be known as the Starship factory’s ‘midbay.’ Standing around 45m (~150 ft) tall, the midbay was designed to support the process of assembling Starship tank sections from several stacks of 2-4 steel rings but was – for whatever reason – left too short to support the full Starship assembly process.

Instead, once Starship tank sections were finished, they would have to be rolled out of the midbay for nose installation. Eventually, in July 2020, SpaceX began assembling an even larger ‘high bay’ that would ultimately measure 81m (~265 ft) tall and 20-25m (65-80 ft) wide and deep – easily big enough to fit the company’s existing Falcon 9 or Falcon Heavy rockets with room to spare. More importantly, of course, the high bay was built to be large enough to support Super Heavy assembly from start to finish, giving SpaceX teams a sheltered place to build the largest rocket boosters in history.

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As of August 2021, SpaceX’s midbay has supported the assembly of 10 Starship prototypes, 5-6 propellant storage tanks, and several ‘test tanks,’ while the newer high bay has helped SpaceX build three (mostly) complete Super Heavy boosters in 2021. However, working at full speed, SpaceX’s midbay is really only capable of supporting the assembly of one Starship tank section (and more general work on two) at a time and the high bay – while offering at least twice the covered surface area – appears to be limited to simultaneous work on two or three different stacks (boosters, ships, tanks, etc.).

As SpaceX slowly but surely treks towards the end of approximately two years almost exclusively dedicated to building ever-changing prototypes, it’s been clear for a while that the company would need to drastically expand its production facilities to produce the dozens of Starships and boosters CEO Elon Musk has been publicly dreaming of. Even at lower volumes, those existing facilities – while great for producing a dozen or more prototypes per year – would still become a chokepoint for the near-term production of a small fleet of operational Starships and Super Heavies.

In turn, Musk revealed that SpaceX was about to start building “a much larger high bay” adjacent to the existing structure in late July. On August 20th, a little over a year after assembly of the original high bay kicked off, SpaceX began the process of tearing up existing concrete for the even larger bay – breaking ground, at least in a sense. According to Musk, the newest addition to Starbase’s Starship factory will be about 10% taller (~90m vs 81m), substantially wider, and likely a bit deeper than the existing high bay, allowing for the installation of two side-by-side bridge cranes with tracks running the full width of the building.

With at least 2-3 times more surface area than the high bay, the new wide bay should give SpaceX enough space to simultaneously assemble something like 4-8 Starships or Super Heavy boosters. Depending on which direction SpaceX goes, the wide bay could also potentially be large enough for SpaceX to create the first true Starship and Super Heavy assembly lines, though that would be a substantial departure from Starbase’s existing approach to manufacturing.

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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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Tesla makes a massive change to a Service policy that owners will love

If you have a subscription to Full Self-Driving or Premium Connectivity for 30 days, the date of its expiration is 30 days after you activate the subscription, even if the vehicle was in service.

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4 hours ago

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October 26, 2025

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Credit: Tesla

Tesla has decided to update its policy on Subscriptions and Service, and owners are going to love it.

If you have a subscription to Full Self-Driving or Premium Connectivity for 30 days, the date of its expiration is 30 days after you activate the subscription, even if the vehicle was in service.

So, if your car was with Tesla Service for five days, you essentially lost those five days, as your expiration date was not adjusted to reflect the time the vehicle was unusable.

Loaners that Tesla gives owners are usually equipped with perks like Full Self-Driving and Premium Connectivity, so your subscription does not roll over to another vehicle.

Tesla launches new loaner program that owners will love

However, Tesla has decided to revise that policy in an effort to give owners full access to the subscriptions they paid for. It requires Service visits to be longer than one day.

In a communication to an owner who was having their vehicle serviced, Tesla said:

“A loaner vehicle may be available during your appointment (pending availability) – please check the app closer to your appointment for the latest updates and access details. If your repair requires more than one business day, any active subscriptions or free trials will be extended accordingly.”

The move is a good one from a customer service standpoint, especially considering the loss of even a few days of a 30-day subscription to something like Full Self-Driving, which costs $99 per month, can be frustrating.

Tesla’s choice to extend the subscription duration for the length of the service visit is a good-faith move that customers will appreciate.

While this adjustment is not directly related to Service, many customers will relate it to that. It’s yet another move Tesla has made in 2025 to make its Service experience better for customers.

It is also offering more options to communicate with Service advisors during and after cars are repaired, which can help streamline the entire visit from start to finish.

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SpaceX reaches incredible Starlink milestone

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5 hours ago

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October 26, 2025

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Credit: SpaceX

SpaceX has reached an incredible milestone with its Starlink program, officially surpassing 10,000 satellites launched into low Earth orbit since starting the program back in 2019.

Last Sunday, October 19, SpaceX launched its 131st and 132nd Falcon 9 missions of 2025, one from Cape Canaveral, Florida, and the other from Vandenberg, California.

The 10,000th Starlink satellite was aboard the launch from California, which was Starlink 11-19, and held 28 v2 mini optimized satellites.

The achievement was marked by a satellite tracker developed by Jonathan McDowell.

The first Starlink launch was all the way back on May 23, 2019, as SpaceX launched its first 60 satellites from Cape Canaveral using a Falcon 9 rocket.

Of the over 10,000 satellites in orbit, the tracker says 8,608 are operational, as some are intentionally de-orbited after becoming faulty and destroyed in the atmosphere.

SpaceX has truly done some really incredible things during its development of the Starlink program, including launch coverage in a global setting, bringing along millions of active subscribers that use the service for personal and business use, locking up commercial partnerships, and more.

Starlink currently operates in around 150 countries, territories, and markets and is available at least somewhere on all seven continents.

Additionally, Starlink has over 5 million subscribers worldwide, and 2.7 million have joined the program over the past year. It has revolutionized internet access on commercial aircraft as well, as several high-profile airlines like Qatar and United, among many others, have already installed Starlink on some of their planes to deliver more stable connectivity for passengers and crew.

SpaceX has the approval to launch 12,000 Starlink satellites from the FAA, but it plans to bring over 30,000 to its constellation, giving anyone the ability to have access to high-speed internet.

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Tesla Full Self-Driving’s biggest improvements from v13 to v14

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7 hours ago

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October 26, 2025

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Credit: Tesla

Tesla Full Self-Driving (Supervised) v14 has been out for several weeks now, and there are a tremendous number of improvements, as we have now reached the fourth iteration of the semi-autonomous software.

Tesla began the v14.1.4 launch last night, which included minor improvements and addressed brake-stabbing issues many owners have reported. In my personal experience, the stabbing has been awful on v14.1.3, and is a major concern.

However, many things have improved, and only a couple of minor issues have been recurring. Many of the issues v13 addressed are no longer an issue, so Tesla has made significant progress.

Here are some of the most notable improvements Tesla made with v14 from v13:

Better Lane Switching on Highways

One of my biggest complaints with v13 was that the “Hurry” Speed Profile would often stay in the left lane, even when there were no passing cars. The legality of cruising in the left lane fluctuates by jurisdiction, but my personal preference is to drive in the right lane and pass on the left.

That said, Tesla has improved FSD’s performance with more courteous lane behavior. It no longer camps in the left lane and routinely gets back in the right lane after passing slower cars.

More Awareness for Merging Traffic and Makes Courteous Moves

There have been times when FSD has been more aware of merging traffic, and even cross traffic, than most human beings.

Here are a few examples –

  • Full Self-Driving lets a car out of cross traffic during a busy time of day. This road tends to get very congested, especially during rush hour, so the car that was let in by FSD would have been sitting there for likely a minute longer if my Tesla had not let him in:

  • A busy, four-lane expressway with a quick exit on the far side of the highway for this merging vehicle. I’ve seen some drivers be extremely inattentive and travel at the same speed as merging cars, making their entry onto the expressway less seamless. FSD doesn’t do that; it makes way for merging cars:

More Confident Driving Around Mail Trucks…and Amish

I encounter a lot of Amish in my area of Pennsylvania, and they commonly use both shoulders and the road, so traffic can get congested at times.

In the past, I’ve taken over when encountering Amish buggies, mail trucks, or other vehicles that are moving slowly or making frequent stops. I have felt it is more logical to just take over in these situations.

I decided not to yesterday on a long drive through Lancaster, PA, and the FSD did a wonderful job of confidently overtaking these vehicles:

This was really impressive and fun to see. There was a slight stutter during one of the three instances, but overall, I didn’t have any concerns.

Object Avoidance

On v13, I almost let the car drive into a fallen branch in the middle of the road. A mile later, the car swerved out of the way for horse droppings. It was a beautiful, clear morning, and the fact that the car did not try to avoid the branch, but did steer away from poop, was concerning.

Tesla has obviously done a great job at refining FSD’s ability to navigate around these road hazards. Last night, it swerved around a dead animal carcass in the middle of the highway. I didn’t see it until we were already going around it:

It was awesome to see this and never feel alarmed by the sharp movement. The maneuver was smooth and really well done.

Better Speed Consistency

With v13, I felt I had to constantly adjust the Speed Profile, as well as the Max Speed setting, when using FSD. With V14, I don’t feel like I am making as many adjustments.

Tesla axed the Max Speed setting altogether with v14, which was a good move, in my opinion. Choosing the Speed Profile is now more intuitive by using the right scroll wheel. If the car is traveling too fast or too slow, just change the profile.

Three things Tesla needs to improve with Full Self-Driving v14 release

V13 had some issues with local roads, and I felt it would travel at strange speeds. In a 45 MPH zone, it would sometimes take a long time to reach 40 MPH, then hover between 43 MPH and 47 MPH. It would then fluctuate between those two speeds, frustrating drivers behind me, understandably.

V14 gets up to speed much better and travels at speeds I’m much more comfortable with on both local roads and highways.

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