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SpaceX’s next big BFR spaceship part finished in Port of LA tent facility

SpaceX's first BFR spaceship prototype is coming together piece by piece. (SpaceX/Pauline Acalin)

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The first 9-meter (29.5-foot) diameter composite propellant tank dome for SpaceX’s full-scale BFR spaceship prototype has been spotted more or less complete at the company’s temporary Port of Los Angeles facility, unambiguous evidence that SpaceX is continuing to rapidly fabricate major components of its next-generation rocket.

Speaking at a dedicated BFR update event in mid-September, CEO Elon Musk foreshadowed as much, and recent updates have reiterated just how committed SpaceX is to BFR and just how keen the company is to waste no time at all.

SpaceX’s first Big F_____ Spaceship (officially Big Falcon) is being built piece by piece inside a large tent in the Port of Los Angeles. (SpaceX)

“We’ve built the first cylinder section…and we’ll be building the domes and the engine section soon.” – SpaceX CEO Elon Musk, September 2018

During that September 17th presentation, Musk did not parse his words despite a self-admitted tendency to look at SpaceX’s development program timelines (Falcon 9, Falcon Heavy, Dragon, BFR) through rose-tinted glasses. Just two months after he uttered the quote above, SpaceX has visibly either finished or nearly finished a 9-meter diameter BFR spaceship (BFS) tank dome.

Due to SpaceX’s opaque treatment of development programs (both literally for the tent and figuratively for official updates), it’s possible that this may even the second dome completed so far. Either way, it can be extrapolated – assuming that the layout of BFR 2017 is generally representative of BFR 2018 – that the first spaceship prototype will require two or three roughly identical tank domes. If the common-dome tank layout is basically the same (disclaimer: it might be quite different), then SpaceX may end up mounting BFS’ 7 Raptor engines almost directly to the rear of the bottom tank dome, requiring either significant structural reinforcement or a second uniquely-engineer and optimized dome.

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Judging from SpaceX’s and Musk’s desire to make reusable rockets as reliable as (if not even more reliable than) commercial airliners, the safest form of mass-transit humans have created, it seems more likely than not that Raptor and BFR will continue SpaceX’s practice of quite literally surrounding each engine with thrust-transmitting structures that simultaneously act as armored shields. In the event that a Merlin engine fails on Falcon 9 or Heavy, each booster’s octaweb contains nine separate armored chambers that exist to isolate each engine in the event of a catastrophic failure. In fact, a Merlin failure – the only such in-flight failure known – during SpaceX’s CRS-1 Dragon launch in 2012 demonstrated the efficacy of this design, preventing the failure of just one of nine engines from causing total mission failure.

Rise of the ‘hexaweb’?

To replicate that design strategy on BFR (both booster and spaceship) would be an act of simple pragmatism – it’s always preferable to design for survivability and reliability than to couch launch and mission success primarily on the reliability of individual components. Because SpaceX chose not to share similarly detailed cutaways of BFR’s updated 2018 design, it’s unclear if the spaceship’s engine section (“hexaweb”, to borrow from “octaweb”) has changed dramatically.

Given the unexpected decision to move entirely away from a version of Raptor specifically optimized for vacuum operation for BFR’s first iteration, as well as the new presence of ~90 cubic meters of storage bins around the circumference of the spaceship’s aft, it’s possible that SpaceX will opt for a design more reminiscent of the Falcon family’s octaweb.

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Regardless, the appearance of a completed BFS tank dome is a major development on the vehicle’s path to integrated testing and paves the way for the fabrication of additional tank domes, barrel sections, engine sections, and more. Particularly obvious and noteworthy will be the fabrication of the prototype spaceship’s pointed cone-shaped nose section, its large tripod fins/wings/legs, and its two forward canard wings.

With all three fins/wings installed, BFS – in its current iteration – would have an unbelievable circumference of ~67 meters (220 feet) and a ‘finspan’ of perhaps 21 meters (~70 feet) tip to tip. BFS is going to be a very hard spaceship to hide.

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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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

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The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

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Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

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Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

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Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

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“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

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From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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