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SpaceX begins launch pad upgrades for Starship flight tests in Texas and Florida

SpaceX has begun outfitting its Boca Chica, Texas launch facilities with hardware meant for Starship Mk1's first flights. (NASASpaceflight - bocachicagal, SpaceX)

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Beneath the buzz of Starship Mk1’s glamorous wing installation, SpaceX has begun installing new launch pad hardware meant to support the spacecraft’s first flights, several components of which have been in Boca Chica for more than a year.

Simultaneously, SpaceX broke ground on a complimentary Starship launch facility on September 21st, an add-on to the existing LC-39A pad in Cape Canaveral, Florida and the probable site of Starship’s first Super Heavy-supported orbital launch attempts.

SpaceX’s Starship-related progress at Pad 39A was noted and photographed by Julia Bergeron on September 21st during one of the hour-long bus tours offered by Kennedy Space Center’s Visitor Complex (KSCVC). SpaceX has been staging hardware at the proposed location of its Pad 39A Starship launch mount over the last ten or so days and finally broke ground (i.e. actually moved earth) on Saturday, a likely indicator that the company was waiting on an official go-ahead or construction permit.

The work at 39A could take anywhere from a few dozen weeks to 6-12 months depending on how substantial the changes are and how permanent SpaceX wants the facilities to be. For the time being, SpaceX applications show a fairly minimal series of modifications, including a concrete pad, a steel launch mount and water-cooled rocket exhaust diverter, a methane farm and associated plumbing, extensions of existing oxygen/nitrogen/helium ground systems, and a few stormwater management-related items.

At the same time, SpaceX is planning to transport its Starship Mk2 prototype – currently staged at a Cocoa, FL assembly facility – several dozen miles to Pad 39A as early as this month, although October is looking more likely. It appears that SpaceX has diverted a large portion of its Florida Starship workforce to Texas in an attempt to expedite Starship Mk1 integration, but SpaceX Cocoa has already fabricated nearly two-dozen steel rings and is likely far ahead of Boca Chica on the road to the first Super Heavy prototype. Barring calamity, Starship Mk1 is nevertheless all but guaranteed to beat Mk2 to flight.

Entering ‘Phase 2’

Back in Boca Chica, Texas, SpaceX ground engineers and technicians are working to upgrade the site’s existing launch facilities, previously used to support an extremely fast-paced campaign of Starhopper wet rehearsals, Raptor static fires, and hops. Starhopper completed its second and final flight on August 27th and the low-fidelity prototype will be retired either as a monument or a static Raptor test stand. Although the existing pad hardware was more than enough for Starhopper, Starship is much larger and has new needs that demand a few upgrades.

Phase 2 is pictured here. Generally speaking, Starship Mk1 mainly needs a lot more propellant than Starhopper. (SpaceX)

Along the lines of its proposed Phase 2 modifications, partially pictured above, SpaceX delivered two massive, new propellant tanks (one for methane, one for oxygen) on September 19th and September 22nd. Somewhat fittingly, those tanks marked the first major rocket-related SpaceX movement in Boca Chica after a long period of inactivity, and their deliveries in July and October 2018 rekindled the excitement surrounding the company’s South Texas launch site.

Both tanks are pictured here at a nearby storage, power, and communications facility in November 2018. (NASASpaceflight – bocachicagal)
Almost a year later, SpaceX’s main Starship propellant storage tanks were moved from storage to the Boca Chica launch facilities on Sept 19 and 22. (NASASpaceflight – bocachicagal)

It remains to be seen whether SpaceX will revamp its current pad with a full concrete foundation and the nature of the Phase 2 pad’s launch mount and water deluge is also unclear. However, the upgrades do appear to be minimal and should take no more than a few weeks to a few months. SpaceX CEO Elon Musk wants Starship Mk1 ready for its first flight tests as early as October 2019 and the company has filed for FCC communications permits that indicate a no-earlier-than (NET) date of October 13th.

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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 Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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