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Relativity Space’s first 3D-printed rocket booster passes early tests

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4 years ago

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Relativity Space CEO Tim Ellis says that the startup’s first 3D-printed ‘Terran-1’ rocket booster has already completed a few significant tests after arriving at its Florida launch pad last month.

Terran-1 is an expendable two-stage launch vehicle that, when assembled for the first time, will measure around 33 meters (110 ft) tall, 2.3 meters (7.5 ft) wide, and weigh 9.3 tons (~20,500 lb) empty. Fueled by liquid oxygen and methane (methalox) and powered by nine small Aeon engines, the first Terran booster will produce around 90 tons (~200,000 lbf) of thrust at liftoff. Altogether, the rocket is designed to initially launch up to 1.25 tons (~2750 lb) to low Earth orbit, with plans to expand to 1.5 tons (~3300 lb) in the future. SpaceX’s Falcon 9, for context, measures 3.7 meters (12 ft) wide, 70 meters (~230 ft) tall, likely weighs around 30 tons (~65,000 lb) dry, and can launch 22.8 tons (~50,250 lb) to LEO in an expendable configuration. A single one of its nine Merlin 1D booster engines produces about as much thrust as the entire first stage of Terran-1.

While tiny in comparison, Terran-1’s booster is still a relatively large and powerful rocket, and testing it poses significant challenges. Instead of building a custom test stand elsewhere, Relativity has chosen to conduct almost all first-stage qualification testing at its Cape Canaveral Space Force Station (CCSFS) LC-16 pad. 

That plan increases the risk of the rocket damaging Relativity’s only available launch pad, significantly delaying launch preparations, but it also has the potential to save time by doubling as a launch pad shakedown. Aside from basic concrete features and foundations, LC-16 was essentially a blank slate when Relativity arrived, so qualifying the pad – virtually all of which is new and recently installed – is no small feat on its own.

LC-16, 2022. (Relativity Space)

Relativity’s first Terran-1 flight hardware has performed shockingly well. The smaller single-engine upper stage sailed through a full program of proof tests – including a full-duration static fire – shortly before shipping to LC-16. Terran-1’s first booster, meanwhile, left Relativity’s California factory and arrived at LC-16 to begin its own qualification testing in early June.

A frosty, venting Terran-1 booster is pictured during one of its first cryogenic tests. (Tim Ellis)

On June 28th, CEO Tim Ellis revealed that the booster had already completed “pneumatic proof testing” and made it through its “first propellant loading” test less than a month after arriving at LC-16. That would be fast for the first prototype of any new orbital-class rocket, but Relativity’s Terran-1 has an extremely unique feature that makes that speed even more impressive: by mass, the vast majority (85%) of the rocket was manufactured with 3D printing. In effect, most of Terran’s airframe and tanks are just giant, continuous welds that were precisely manipulated into cylinders, domes, and more. While the rough surface finish leaves something to be desired and likely reduces the overall efficiency of the rocket’s airframe, Relativity says that the composition of the metal in its printed structures is almost identical to a more traditionally-manufactured component.

Relativity’s ultimate hope is that the technical groundwork it is laying will allow it to manufacture complex and high-performance rockets with minimal human intervention, drastically lowering production costs. One day, the descendants of those semi-autonomous factories might even be used to construct rockets and other complex machines and infrastructure on Mars or other extraterrestrial destinations.

First, though, the company needs to start successfully launching Terran-1 rockets and fully prove the concept. Up next, Relativity will likely perform a full wet dress rehearsal, a launch simulation in which the rocket is loaded with propellant and pressurized for flight. Once that step is complete, Relativity will attempt one or several static fire tests, culminating in a full-duration multi-minute static fire or “mission duty cycle.”

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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 Model Y L’s new features flexed at unveiling event at Diner

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15 hours ago

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July 31, 2026

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Tesla Model Y L in a field
Credit: Tesla

Tesla flexed the new features of the Model Y L with a dedicated media event at the company’s Diner on Santa Monica Boulevard in Los Angeles.

The Model Y L is the extended-wheelbase version of the all-electric crossover, which has been voted the best-selling car in the world on three occasions. The vehicle is already rolling off production lines at Gigafactory Texas, and first deliveries are slated to take place later this year.

Tesla brings Model Y L ‘Launch Series’ to the U.S. at $61,990

Teslarati was invited to the event, but due to some scheduling conflicts, we could not make it to Los Angeles. Instead, we will have our hands on a media unit sometime in August, so we’ll be able to spend some more extended time with the Model Y L.

However, plenty of those who made it to LA shared some cool features that set the Model Y L apart from the Model Y.

Multi-Row Climate Control

Tesla fitted the Model Y L with full climate control on all three rows on the front screen. It can be adjusted by selecting which row you’d like to modify on the right-hand side of the touch screen:

Better Rear Window Visibility

One of the strangest things about the Model Y, especially the Juniper iteration, is the rear window has extremely limited visibility when looking into the rearview mirror.

Tesla has improved upon this with the Model Y L:

PowerShare will be included

Model Y L will come with PowerShare in North America, with an 11.5kW output to your home. Tesla said it would require Powerwall 3 for operation.

Wireless Charging Pad

There has been some speculation that Tesla would upgrade the wireless charging pads in the United States, but this is not the case.

Tesla owner fixes common feature complaint with crafty DIY retrofit

Tesla confirmed that it does not come with the cooled pads as the Y L in China does. This is because North America has not adopted Qi charging yet.

Thermal Management Improvements

These improvements in the Model Y L were seen with thermal management:

  • Up to 15% faster cabin cooling
  • +23% thermal efficiency gained in hot weather, 7 miles of real-world range gained
  • 8x more solar energy reflection off of glass roof
  • 30% reduction in solar energy entering the cabin

Demand

Tesla said the Model Y L is almost sold out in the U.S. It comes with

  • 1 year of FSD Supervised
  • 1 year of Supercharging
  • 1 year of Premium Connectivity
  • Free exterior paint color, interior, and wheel option at no additional cost
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Elon Musk

Tesla CEO Elon Musk denies ridiculous Gigafactory Shanghai rumor

Published

17 hours ago

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July 31, 2026

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(Credit: Tesla)

Tesla CEO Elon Musk took to his social media platform X on Thursday night to deny a ridiculous rumor regarding the sale of the company’s Chinese vehicle production plant, Gigafactory Shanghai.

On Thursday, the Wall Street Journal, citing sources familiar with the matter, claimed in a scathing new report that Tesla was exploring a potential sale of the entire China business in an effort to help bolster a potential merger between SpaceX and Tesla.

Musk immediately denied the rumor not once but twice, initially calling it “fake news,” and then calling it “absurdly fake news” in a separate post just a few moments later:

The original poster of the Wall Street Journal article that Musk saw deleted the initial post sharing the headline and the rumored sale of Tesla’s China business.

The report seemed absolutely and unequivocally false to begin with; Tesla’s business in China is among the most important pieces of the company’s business. Not only does the factory supply vehicles for the domestic market, but also for various other markets in Asia and Europe.

China is also one of the largest automotive markets in the world, and Tesla has performed well there despite the robust competition.

The speculation regarding a Tesla and SpaceX merger has started to gain steam this year as the space exploration company went public just a month ago. There has been speculation that Musk will bridge all of his companies under one “umbrella company,” and analysts believe this could happen before the end of the decade.

The Tesla and SpaceX merger everyone is talking about is quietly building

This is the latest iteration of Musk’s very evident war on mainstream media. Reports regarding any of Musk’s companies are quick to get the dreaded “false” or “fake news” response from the CEO when they are unfounded.

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Elon Musk

Tesla AI boss reveals how big Optimus is going to get

Tesla’s Optimus chief corrected himself on X, confirming a staggering 10 million robot production target.

Published

1 day ago

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July 31, 2026

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla’s Optimus program has a new number attached to it, after Ashok Elluswamy, the executive who has run the humanoid robot program since June 2025, posted a three word correction on X Thursday, “Correction, 10 million robots.”

The line clarifies the long term annual capacity Tesla is building toward its planned second Optimus production line at Gigafactory Texas, a figure Musk has cited repeatedly since last year’s shareholder meeting.

The scale is worth noting, because ten million robots a year would mean Tesla building more units annually than most countries sell in new cars. Tesla has framed this as a second line, not the first. The buildout is happening in two phases: a roughly one million unit per year line inside Tesla’s Fremont factory, installed on the floor space vacated when Model S and Model X production ended earlier this year, and a much larger dedicated facility under construction at Giga Texas that broke ground on its first steel structure in May. That Texas facility is the one Elluswamy’s correction refers to, and is expected to reach volume production sometime in 2027.

Tesla Optimus project fires up as Musk sees production line progress

Elluswamy took over Optimus from Milan Kovac last summer and has spent the months since talking up the program’s trajectory. Elon Musk has also floated the ten million figure at Tesla’s 2025 shareholder meeting.

Ending Model S and Model X production to make room for the first Optimus line was one of the more consequential manufacturing decisions in the company’s recent history, retiring two flagship vehicles in favor of a robot that has yet to enter mass production. Musk has previously estimated per unit production costs at $20,000 to $25,000 once Tesla reaches a million units a year, though he hasn’t said what that cost looks like at ten times the volume.

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