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SpaceX moving fast on Mars rocket development, BFR tent spied with more tooling

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Photos taken by Teslarati photographer Pauline Acalin have confirmed that SpaceX’s massive Mars rocket fabrication tooling has been hiding in plain sight at the company’s Port of San Pedro tent facility.

Spotted inside the temporary structure thanks to open flaps and a human desire for a breeze amidst the warm Los Angeles springtime, the main cylindrical component is truly vast – large enough that the eye almost glazes over it at first glance. Dwarfing the humans clambering about it, very rough estimates using knowledge of the tent’s reported area (20,000 square feet) and size comparisons with machinery blueprints suggest a diameter of around 8-10 meters (26-36 feet), loosely conforming to the expected 9m diameter of BFR, as of CEO Elon Musk’s IAC 2017 update. Recently, however, President Gwynne Shotwell showed off an updated Mars rocket video at TED2018 that led to Musk hinting that BFR may have grown slightly since then.

SpaceX’s massive BFR manufacturing tool peeked out from the company’s Port-side tent facility. (Pauline Acalin)

The massive cylindrical structure teased by Musk earlier this month is most likely a mandrel, a tool that can be spun on its horizontal axis to weave predetermined structures. In the case of the Mars rocket mandrel, it will likely be used to carefully wind dozens or hundreds of layers of carbon fiber (known as prepreg), interspersed with layers of laminate and various epoxies and resins. It’s also possible, however, that the massive tool is instead a multipurpose mold and autoclave, where the composite layers would be lain on the inside of the cylinder, allowed to set, and eventually sealed inside and heat/pressure treated.

Images of the machinery are fairly ambiguous: they show a structure that could have connection points one might find on an autoclave, as well as what appears to be a thick and well-insulated internal wall. However, the external skin appears to be a relatively thin sheet of metal, which would point more towards a traditional composite mandrel, where certain sheets could be removed or modified as needed to create desired shapes in the composite while it’s being formed, less risky than machining a completed segment.

 

Perhaps even more interesting, a number of massive metal structures were spotted just outside of the tent. While it is unclear what exactly their purpose was, is, or will be, it’s more likely than not that they are components of a carbon composite mold or layup structure meant to deal with fabrication of certain Mars rocket and spaceship components with complex curves, versus the relatively simple cylinders that BFR and BFS are largely comprised of. Still, precedents exist in large aerospace composite manufacturing for the fabrication of structures with complex curves, most notably the nose and front sections of airliners like Boeing’s 787.

Finally, it’s worth noting just how shockingly busy the BFR tent was on both April 13th and 14th, as well as the 8th (the first day Pauline visited the facility). With upwards of 40 cars parked at the tent, it’s blindingly clear that SpaceX is not simply using the tent as a temporary storage location – alongside the arrival of composite fabrication materials (prepreg sheets, epoxy, etc) from Airtech International, SpaceX undeniably intends to begin initial fabrication of the first BFR prototypes in this tent, although they will likely eventually move the activities to the Berth 240 Mars rocket factory. That’s certainly not a sentence I ever expected to write, but it is what it is.

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Eric Ralph Twitter

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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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

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Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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