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SpaceX goes all-in on steel Starship, scraps expensive carbon fiber BFR tooling

SpaceX's Port of LA-based BFR development tent is no more after the company presumably decided to scrap the entirety of it and its contents, March 14th. (Pauline Acalin)

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In a wholly unforeseen turn of events, SpaceX has taken the extraordinary step of permanently scrapping both its Port of Los Angeles-based BFR development tent and what seem to be the majority of what it contained, irreparably destroying custom-built tooling meant to support the fabrication of carbon composite BFR spaceships and boosters.

Likely worth anywhere from several to tens of millions of dollars (USD), SpaceX’s advanced BFR production tools were procured from industry-expert Ascent Aerospace sometime in 2017 before being officially delivered to the rocket company’s newly-erected Port of LA tent around April 2018. Situated at the port specifically due to logistical concerns about the high cost of transporting 9m/30ft-diameter objects from SpaceX’s main Hawthorne facilities to a barge for transport east, the company has decided to unequivocally destroy its aerospace-grade composite tooling less than 12 months after accepting delivery. Put simply, this is the best evidence yet that SpaceX – willing or not – has gone all-in on build Starship and Super Heavy out of stainless steel less than six months after CEO Elon Musk began to hint at the program’s utterly radical pivot.

SpaceX’s Port of LA-based BFR development tent is no more after the company presumably decided to scrap the entirety of it and its contents, March 14th. (Pauline Acalin)

From the very beginning of SpaceX and Elon Musk’s serious pursuit of an entirely reusable launch vehicle capable of transporting dozens of astronauts and passengers to and from Earth and Mars, the plan had been to build the vast majority of the rocket’s booster and spacecraft structures out of advanced carbon fiber composite materials. Above all else, this fundamental architecture was motivated largely by the significant performance gains a rocket could achieve by replacing traditional aluminum tanks and structures with carbon fiber.

For a rocket (and especially an orbital spaceship) meant to somehow make Earth-Mars transport both routine and at least minutely affordable, focusing primarily on the optimization of the mass of cargo delivered relative to the empty weight of the spaceship and booster made (and still does make) a great deal of sense. Assuming that the reusability of a system is roughly constant, the only conceivable way to further lower the cost of price per unit of cargo or passenger ticket would be to increase the usable cargo/passenger capacity for each individual launch, making an extremely light and high-performance rocket the low-hanging fruit target.

Musk revealed the first iteration of BFR – known as the Interplanetary Transport System (ITS) – in 2016. Carbon fiber structures featured prominently. (SpaceX)
SpaceX even built a full-scale, 12m/40ft-diameter carbon composite liquid oxygen tank to begin the process of tech development. (Reddit)

The centrality of carbon fiber composites remained with SpaceX’s Sept. 2017 iteration of BFR, downsized by 25% to a diameter of 9m (~30 ft). Around six months later, that commitment to composites was further solidified by the delivery of the first 9m-diameter carbon fiber tooling in March or April 2018. The tooling used to mold and lay up aerospace-grade advanced carbon fiber structures is inherently expensive, demanding extremely low tolerances across massive surface areas and volumes in order to ensure the quality of the equally massive and low-tolerance composite structures they are used to build. Actual prices are often closely guarded and difficult to determine or extrapolate off of, but it’s safe to say that SpaceX likely spent months of effort and at least several million dollars to acquire its large BFR mandrel.

In the subsequent months of 2018, SpaceX’s BFR and composite R&D team spent tens of thousands of hours building out an ad-hoc advanced composites workshop inside a temporary tent in an industrial area, and ultimately managed to build a number of full-scale carbon fiber segments, including at least one large tank barrel section and the beginnings of a tank dome. In September 2018, that progress was partially revealed alongside the announcement that Japanese billionaire Yasuka Maezawa had purchased the first crewed lunar launch of BFR for several hundred million dollars, set to occur no earlier than 2023.

Two months after indicating that the first BFR “airframe/tank barrel section” would be built out of a “new carbon fiber material”, Musk provided the very first teaser for a “counterintuitive” development that would later be identified as the CEO’s decision to wholly replace BFR’s proposed used of composites with stainless steel and an advanced metallic heat shield. Still more than a little controversial and hard to follow almost half a year later, the feeling at the time was that SpaceX’s eccentric leader had decided to throw away more than 24 months of composite BFR design and development work for an almost entirely unproven alternative approach.

For better or for worse, it appears that SpaceX (or maybe just Musk) has quite literally trashed the most concrete demonstration of a prior commitment to advanced carbon fiber composites, scrapping the vast majority of its composite tooling and perhaps even the prototype BFR segments built in 2018.

RIP BFR mandrel and tent, we barely knew ye. (Pauline Acalin)

It remains to be seen whether the now-permanent decision to pursue a stainless steel design in place of carbon fiber was a very expensive mistake, a stroke of genius, or something in between, However, the undeniably brisk progress made with the BFR’s steel variant in last four or so months bodes well – at a minimum – for Musk’s optimism that this radical change will ultimately result in an operational vehicle far sooner (and presumably cheaper) than the composites route.

Generally speaking, it seems safe to – on the face of it – agree with Musk’s argument that steel should ultimately lend itself far more easily to reusability thanks to its high tolerance for extreme temperatures. Unlike Falcon 9’s aluminum structures (and even the most exotic, advanced carbon fiber composites), certain varieties of stainless steel can weather heating approaching that experienced during orbital reentry with minimal erosion or damage to its mechanical properties. As Musk puts it, the Super Heavy booster’s suborbital trajectory could require almost no heat shielding – and perhaps even paint – at all.

Only time will tell whether the inevitably harsher realities of real-life engineering are so kind. In the meantime, SpaceX is perhaps just hours away from the first attempted static-fire test of a Raptor installed on something approaching flight-hardware, in this case a full-scale Starship hop test prototype.

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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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SpaceX moves to challenge AT&T, Verizon with Qualcomm-powered 5G

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Credit: Qualcomm

SpaceX has selected Qualcomm Technologies to supply core infrastructure for Starlink Mobile’s planned nationwide terrestrial 5G network in the United States.

Announced on November 4, the multi-year agreement covers radios, baseband units, and commercial-grade Layer 1 software based on Qualcomm’s Dragonwing Cellular Infrastructure platforms, specifically the QRU100 and QDU100:

These will power Massive MIMO radio units featuring 64 transmit and 64 receive paths (64T64R), designed to boost coverage, capacity, and spectral efficiency at scale. Qualcomm has described the pact as its largest 5G deal to date, with deployment across tens of thousands of U.S. cell sites scheduled to begin in 2027.

The terrestrial build-out is meant to complement, not replace, Starlink’s satellite direct-to-cell capabilities. SpaceX has assembled substantial spectrum holdings for this purpose: roughly 65 MHz of mid-band frequencies acquired from EchoStar (including AWS-4 and related bands) and up to 14 MHz of low-band 800 MHz spectrum from Grain Management.

The low-band airwaves improve indoor penetration and range, while mid-band supports higher capacity. SpaceX executives, including President Gwynne Shotwell, have outlined a hybrid architecture in which satellites eliminate outdoor dead zones and terrestrial nodes add capacity where demand is highest.

Earlier comments suggested small cells or femtocells potentially co-located with existing Starlink user terminals on roofs, though later filings also reference more conventional antennas on towers and structures.

The big picture is SpaceX’s bid to become a full-fledged U.S. mobile carrier rather than a satellite partner or dead-zone filler. AT&T, Verizon, and T-Mobile together generate hundreds of billions in annual wireless revenue; Shotwell has said SpaceX expects to win customers by offering superior coverage, including during disasters, through seamless satellite-terrestrial handoff.

Verizon, AT&T and T-Mobile are trying to shut Starlink out before FCC vote

Starlink already represents a major share of SpaceX’s revenue and profit following the company’s 2026 IPO. By vertically integrating spectrum, satellite manufacturing, launch capacity, and now ground radio equipment, SpaceX aims to control more of the connectivity stack.

Qualcomm’s involvement also positions the network for future evolution toward AI-native 6G infrastructure, with energy-efficient processing that could improve deployment economics.

Challenges remain: spectrum depth still lags the Big Three, capital costs for tens of thousands of sites will be substantial, and regulatory approvals continue, but the Qualcomm deal marks a concrete step from spectrum accumulation toward operational network build-out.

In short, the partnership accelerates Starlink Mobile’s shift from orbital broadband specialist to hybrid mobile competitor, testing whether a space-based company can reshape terrestrial wireless economics and coverage in the world’s largest market.

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Elon Musk’s Grok Bot is picking up the phone now, and the first calls are wild

Elon Musk wants Grok Bot users making phone calls, and one Comcast call saved $500.

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Elon Musk is pushing Grok Bot users toward a feature that, until this week, few of them could actually use. “Try asking Grok @Bot to make calls!” Musk wrote on X Tuesday afternoon, quoting a demo from Sawyer Merritt that included audio from a live call.

Musk first announced calling on October 25, writing that the agent could “call someone or a business for you, make a request on your behalf, take notes on the response and send you a note summarizing the conversation.” There were no release notes at the time, and the feature only appeared in preview builds. That changed on Tuesday, when creator Peter Yang said all Grok Bot users should now be able to call US businesses. Musk reposted his demo.

Yang’s call shows how far the feature goes. In his video, his bot dialed Comcast, worked through the phone menu, deflected small talk about the weather by saying it does not “have eyes on the sky,” turned down three upsells and used a cheaper fiber offer from competitor Sonic as leverage. His bill dropped from $84 to $45 per month on a faster plan, a savings of nearly $500 a year. The call ran about 25 minutes, and the bot paused to get Yang’s approval before accepting the final terms.

Merritt described what the user sees: a live transcript runs during the call, and when the business asks for something the bot does not know, an answer box pops up in the chat. The user types a reply and Grok relays it to the person on the line. Other users posted results Tuesday, including a $100 gift card recovered from Verizon Fios after a 51 minute call and a same day pediatric appointment, which Musk also shared. Not every call worked. One user said a rep refused to cancel a subscription once it was clear an AI was on the phone.

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The Grok Bot terms require every call to identify itself as a virtual assistant calling on the user’s behalf and warn that calls may be recorded. Marketing, mass calling and impersonation are prohibited, and calling currently works only with US numbers.

The timing stands out. Days ago, users began hitting their weekly limits early, and Musk said the cost of serving Grok Bot was “unsustainably high relative to revenue,” as Teslarati reported. A call that spends most of its 25 or 50 minutes on hold is the kind of long running task that eats into usage, and SpaceXSI has not said how calls count against the weekly pool. Grok Bot is included from the $30 Premium tier of The X Subscription upward.

For Tesla owners, the agent has been in their cars since September 22 and is enabled across every Cybercab and Model Y Robotaxi. Musk has already pitched it for phone chores like scrubbing your number from spam call lists. Neither Tesla nor SpaceXSI has confirmed whether a bot can place one of these calls on request from inside the vehicle.

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SpaceX’s Starfall just went from secret to storefront

SpaceX now pitches Starfall missions with 1,000 kg payloads, weeks of microgravity, and Starlink connectivity.

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An artist’s illustration of a SpaceX Starfall capsule reentering Earth’s atmosphere. (Image: SpaceX)

SpaceX has put up a dedicated commercial page for Starfall, its disk shaped reentry capsule, laying out for the first time what customers actually get when they book a flight. The page, live at spacex.com/starfall, pitches “affordable, routine access to microgravity” and invites companies to get in touch about flying manufacturing, research or testing payloads.

The specs are short and specific. Each Starfall mission carries up to 1,000 kg of payload, supplies 1 kW of power and connects through an Ethernet interface. Mission length is tailored to the customer, and the payload stays online the entire time through Starlink, which means researchers can pull data from an experiment while it is still in orbit instead of waiting for splashdown.

SpaceX is launching a secret spacecraft that could change how things are made in space

SpaceX is aiming the service at three markets. Biomedical customers are told they can grow stem cell organoids, replacement tissue and layered biomaterials. Pharmaceutical companies are pitched on protein and small molecule drug crystals, which form smaller and more uniform shapes without gravity driven convection. Materials science rounds out the list, with semiconductors and other next generation materials grown in vacuum and microgravity.

The page also makes clear which rocket SpaceX is counting on. “By launching on Starship, Starfall brings a reliable and scalable cadence previously unavailable to the market,” the company wrote, contrasting weeks of continuous microgravity with the seconds offered by drop towers and parabolic flights. No price or first operational flight date is listed.

The commercial push is a sharp turn from how Starfall started. SpaceX said almost nothing about the capsule ahead of its first flight in June, and nearly everything known came from FAA and FCC filings describing a disk about 10.2 feet wide and 2.5 feet tall that can return 2,200 pounds of cargo. By its second flight on the Bandwagon-5 rideshare in October, Starfall was listed by name on the mission page, though SpaceX still did not say what it carried.

Customers appear to be lining up. SpaceX said in its third quarter results that it signed three commercial Starfall missions during the quarter. On the earnings call, President Gwynne Shotwell described the capsule as providing “routine relatively low cost access to microgravity environments for scientific research, including improving our understanding of diseases like cancer and diabetes,” and said the three new missions would fly on Starship.

The branding effort extends past the website. SpaceX added a Starfall T-shirt to its online store on Monday as part of a batch of new merchandise, giving the program a place next to Starship, Starlink and Starshield in the company’s lineup.

The move also puts SpaceX in more direct competition with companies it launches. Varda Space Industries, which has built much of the in-space manufacturing market so far, flew its W-Series 7 capsule on the same Bandwagon-5 mission as Starfall in October. Varda’s capsules are roughly three times smaller than Starfall, and SpaceX controls the ride to orbit for both.

Starfall’s near term cadence depends on Starship. SpaceX is preparing for Flight 15 after completing static fires of Ship 42 and its Super Heavy booster in late October, and is aiming to catch both stages with the launch tower on that flight.

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