Connect with us

SpaceX

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)

Published

on

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.

Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.

Advertisement

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.

Advertisement
Comments

Elon Musk

SpaceX just got pulled into the biggest Weapons Program in U.S. history

SpaceX joins the Golden Dome software group, deepening its role in America’s most expensive defense program.

Published

on

By

US Golden Dome space defense system (Concept render by Grok)

SpaceX has joined a nine-company group developing the core operating software for the Golden Dome, America’s next-generation missile defense system. According to a Bloomberg report, SpaceX is focused on integrating satellite communications for military operations and is working alongside eight other defense and artificial intelligence companies, including Anduril Industries, Palantir Technologies, and Aalyria Technologies, to build software connecting missile defense capabilities.

The Golden Dome concept dates back to President Trump’s 2024 campaign, and on January 27, 2025, he signed an executive order directing the U.S. Armed Forces to construct the system before the end of his term. The system is planned to employ a constellation of thousands of satellites equipped with interceptors, with data centers in space providing automated control through an AI network.

FCC accepts SpaceX filing for 1 million orbital data center plan

Space Force Gen. Michael Guetlein, director of the Golden Dome initiative, has described the software layer as a “glue layer” that would enable officers to manage and control radars, sensors, and missile batteries across services. The consortium is aiming to test the platform this summer.

Trump selected a design in May 2025 with a $175 billion price tag, expected to be operational by the end of his term in 2029, though the Congressional Budget Office projected the cost could reach $831 billion over two decades.

The Golden Dome role is only the latest in a string of military wins for SpaceX. As Teslarati reported, the U.S. Space Force awarded SpaceX a $178.5 million task order on April 1, 2026 to launch missile tracking satellites for the Space Development Agency, covering two Falcon 9 launches beginning in Q3 2027. That came on top of more than $22 billion in government contracts held by SpaceX as of 2024, per CEO Gwynne Shotwell, spanning NASA resupply missions, classified intelligence satellites through its Starshield program, and military broadband.

The accumulation of defense contracts, now including a seat at the table on the most expensive weapons program in U.S. history, positions SpaceX as the dominant infrastructure provider for American national security in space. With a SpaceX IPO still on the horizon, each new contract adds weight to what is already one of the most consequential companies in aerospace history, raising real questions about how much of America’s defense architecture will depend on a single private operator before it ever trades publicly.

Continue Reading

News

SpaceX is following in Tesla’s footsteps in a way nobody expected

In the span of just months in early 2026, SpaceX has transformed itself into one of the world’s most ambitious AI companies. The catalyst: its February acquisition of xAI.

Published

on

Credit: Grok

When Elon Musk founded Tesla in 2003, it was a plucky electric car startup betting everything on lithium-ion batteries and a niche luxury Roadster.

Two decades later, Tesla is far more than a car company. Its valuation increasingly hinges on Full Self-Driving software, the Optimus humanoid robot, the Robotaxi program, and the Dojo supercomputer cluster purpose-built for AI training.

Musk has repeatedly described Tesla as an AI and robotics company that happens to sell vehicles. The cars, in this view, are merely the first scalable platform for real-world AI.

Now, SpaceX is tracing an eerily similar path, only faster and in a direction almost no one anticipated. Founded in 2002 to make spaceflight routine and eventually multiplanetary, SpaceX spent its first two decades perfecting reusable rockets, landing Falcon 9 boosters, and building the Starlink megaconstellation.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

It was an engineering and manufacturing powerhouse, not a software play. Yet, in the span of just months in early 2026, SpaceX has transformed itself into one of the world’s most ambitious AI companies. The catalyst: its February acquisition of xAI.

The xAI deal, announced on February 2, was structured as an all-stock transaction that valued the combined entity at roughly $1.25 trillion—SpaceX at $1 trillion and xAI at $250 billion. In a memo to employees, Musk framed the merger as the creation of “the most ambitious, vertically-integrated innovation engine on (and off) Earth.”

The new SpaceX now owns Grok, the large language model family that powers the chatbot of the same name, along with xAI’s massive training infrastructure. More importantly, it has a declared mission to move AI compute off-planet.

Earth-based data centers are hitting hard limits on power, cooling, and land. Musk’s solution is orbital data centers, or constellations of solar-powered satellites that act as supercomputers in the sky.

SpaceX has already asked regulators for permission to launch up to one million such satellites. Starship, the company’s fully reusable heavy-lift vehicle, is the only rocket capable of delivering the necessary mass at the required cadence.

Each orbital node would enjoy near-constant sunlight, vast radiator surfaces for passive cooling, and zero terrestrial real-estate costs. Musk has predicted that within two to three years, space-based AI inference and training could become cheaper than anything possible on the ground.

This is not a side project; it is the strategic centerpiece Musk has envisioned for SpaceX. Starlink already provides the global low-latency backbone; next-generation V3 satellites will carry onboard AI accelerators. Rockets deliver the hardware, while AI optimizes every aspect of launch, landing, and constellation management.

The feedback loop is self-reinforcing, too. Better AI makes better rockets, which launch more AI infrastructure.

Just yesterday, on April 21, SpaceX doubled down.

It secured an option to acquire Cursor—the fast-growing AI coding tool beloved by software engineers—for $60 billion later this year, or pay a $10 billion partnership fee if the full deal does not close.

Cursor’s models already help engineers write code at superhuman speed. Pairing that technology with SpaceX’s Colossus-scale training clusters (the same ones powering Grok) positions the company to dominate AI developer tools, much as Tesla dominates autonomous driving software.

Why SpaceX just made a $60 billion bet on AI coding ahead of historic IPO

The parallels with Tesla are striking. Both companies began in a single, capital-intensive sector: Tesla with EVs, SpaceX with launch vehicles. Both used early hardware success to fund AI at scale. Tesla’s Dojo supercomputers train neural nets on billions of miles of real-world driving data; SpaceX now trains on telemetry from thousands of orbital assets and re-entries.

Tesla’s FSD chip runs inference on cars; SpaceX’s future satellites will run inference in orbit.

Tesla’s Optimus robot will work in factories; SpaceX envisions lunar factories manufacturing more AI satellites, eventually using electromagnetic mass drivers to fling them into deep space.

Critics once dismissed Musk’s multi-company empire as unfocused. The 2026 moves reveal the opposite: deliberate convergence.

SpaceX is no longer merely a rocket company that sells internet from space. It is an AI company whose competitive moat is literal orbital infrastructure and the only vehicle that can service it at scale. The forthcoming IPO, expected later this year, will almost certainly be pitched not as a space play but as the purest bet on AI infrastructure the public market has ever seen.

Whether the orbital data-center vision survives regulatory scrutiny, astronomical concerns about light pollution, or the sheer engineering challenge remains to be seen.

Yet the strategic direction is unmistakable. Just as Tesla proved that software and AI could redefine the century-old automobile, SpaceX is proving that rockets are merely the delivery mechanism for the next great computing platform—one that floats above the clouds, powered by the sun, and limited only by the physics of orbit.

In that unexpected sense, history is repeating. Tesla stopped being “just a car company” years ago. SpaceX has now stopped being “just a rocket company.” Both are becoming something far larger: AI powerhouses with hardware moats so deep that competitors will need their own reusable megaconstellations to keep up.

The age of terrestrial AI is ending. The age of space-based AI is beginning—and SpaceX is building the launchpad.

Continue Reading

Elon Musk

Why SpaceX just made a $60 billion bet on AI coding ahead of historic IPO

SpaceX has secured an option to acquire Cursor AI for $60 billion ahead of its historic IPO.

Published

on

By

SpaceX announced today it has struck a deal with AI coding startup Cursor, securing the option to acquire the company outright for $60 billion later this year, while committing $10 billion for joint development work in the interim. The announcement described the partnership as building “the world’s best coding and knowledge work AI,” and comes just days after Cursor was separately reported to be raising $2 billion at a valuation above $50 billion.

The move makes strategic sense given where each company currently stands. Cursor currently pays retail prices to Anthropic and OpenAI to the same companies competing directly against it with Claude Code and Codex. That means every dollar of revenue Cursor earns partially funds its own competition. With SpaceX bringing computational infrastructure to the Cursor platform, that could reduce Cursor’s dependence on OpenAI and Anthropic’s Claude AI as its providers. Access to SpaceX’s Colossus supercomputer, with compute equivalent to one million Nvidia H100 chips, gives Cursor the infrastructure to run and train its own models at a scale it could never afford independently. That one change restructures the entire unit economics of the business.

Elon Musk teases crazy outlook for xAI against its competitors

Cursor’s $2 billion in annualized revenue and enterprise reach across more than half of Fortune 500 companies gives SpaceX something its xAI subsidiary currently lacks, which is a proven, fast-growing software business with real enterprise distribution.

For Cursor, SpaceX’s $10 billion in joint development funding is transformational. Cursor raised $3.3 billion across all of 2025 to reach that $2 billion in revenue. A single $10 billion commitment from SpaceX, even as a development payment rather than an acquisition, dwarfs everything Cursor has raised in its entire existence. That capital accelerates product development, enterprise sales infrastructure, and proprietary model training simultaneously.

The timing is deliberate. SpaceX filed confidentially with the SEC on April 1, 2026, targeting a June listing at a $1.75 trillion valuation, in what would be the largest public offering in history. The company is expected to begin its roadshow the week of June 8, with Bank of America, Goldman Sachs, JPMorgan, and Morgan Stanley serving as underwriters. Adding Cursor to the portfolio before that roadshow gives IPO investors a concrete enterprise software revenue story to price in, alongside rockets and satellite internet.

The deal also addresses a weakness that became visible after February’s xAI merger. Several xAI co-founders departed following that acquisition, and SpaceX had already hired two Cursor engineers, signaling where its AI talent strategy was heading. Cursor, for its part, faces a pricing disadvantage competing against Anthropic’s Claude Code.

Whether SpaceX exercises the full acquisition option before its IPO or after remains the open question. Either way, this deal reshapes what investors will be buying into when SpaceX goes public.

Continue Reading