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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.

 

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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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Tesla Cybertruck is officially the safest pickup, IIHS says

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Credit: Tesla

The Insurance Institute for Highway Safety (IIHS) has awarded the 2025-2026 Tesla Cybertruck crew cab pickup its highest honor: Top Safety Pick+. This marks the Cybertruck as the only full-size pickup to achieve this distinction in recent evaluations.

The award applies specifically to vehicles built after April 2025, following structural upgrades including front underbody reinforcements and footwell modifications.

These changes enabled strong performance in updated crash tests. The Cybertruck earned “Good” ratings in the small overlap front (driver and passenger sides), updated moderate overlap front, and updated side tests—core requirements for the Top Safety Pick+ designation.

It also secured acceptable or good headlights across trims and a “Good” rating for its standard front crash prevention system in pedestrian scenarios, along with acceptable or good performance in vehicle-to-vehicle testing.

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The Cybertruck avoided every single pedestrian collision, including:

  • Daytime child crossing
  • Nightitime adult crossing
  • Night parallel adult

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In the large pickup category, competitors such as the Toyota Tundra received only a standard Top Safety Pick, while the Ford F-150 and Ram 1500 did not qualify for either award. This positions the Cybertruck as a standout in occupant protection and crash avoidance among its peers.

Credit: IIHS

Ironically, the same vehicle celebrated for superior U.S. safety performance remains banned from public roads in the United Kingdom and much of Europe. Regulators there cite the Cybertruck’s sharp external edges and highly rigid stainless-steel construction as failing pedestrian-protection standards. European and UK rules require rounded surfaces on protruding parts to minimize injury risk in collisions with vulnerable road users.

Critics also point to the truck’s substantial weight and unyielding body structure, which some argue could transfer more force to other vehicles or pedestrians rather than absorbing it.

Tesla’s engineering philosophy underpins the Cybertruck’s strong IIHS results. The vehicle features a distinctive stainless-steel exoskeleton made from ultra-hard 30X cold-rolled stainless steel. This provides exceptional structural rigidity and a robust safety cage that resists deformation in side impacts and rollovers.

Engineers designed integrated load paths to channel crash forces away from the occupant compartment while allowing controlled energy absorption in key zones. Post-April 2025 refinements to the front underbody further optimized performance in overlap crashes.

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Complementing the passive structure is Tesla’s advanced active safety suite, including the standard Collision Avoidance Assist system with automatic emergency braking. This contributed directly to the vehicle’s strong front crash prevention scores. The skateboard platform and low center of gravity also enhance stability and handling, reducing the likelihood of certain crashes.

The IIHS recognition highlights how Tesla’s combination of high-strength materials, structural innovation, and software-driven safety systems can deliver top-tier protection in rigorous testing. While global regulatory differences on design and pedestrian interaction continue to limit the Cybertruck’s availability outside North America, its U.S. safety credentials set a new benchmark for full-size pickups.

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Elon Musk

SpaceX’s newest Starmind will make earth data centers obsolete

Elon Musk confirmed Starmind as SpaceX’s AI satellite constellation name, targeting one million orbital compute nodes.

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Elon Musk confirmed that Starmind will be the official name of SpaceX’s planned AI satellite constellation, following a trademark filing by xAI that surfaced earlier this week. Starmind is what’s being described to the FCC as a constellation of up to one million AI satellites

It’s worth noting that SpaceX’s Starlink communication satellite and Starmind are built on the same orbital infrastructure concept but serve entirely different purposes. Starlink is a connectivity network, with satellites receiving and relaying data between points on Earth, and functioning as a high-speed internet backbone in space. The satellites themselves do not process or think, and move information from one place to another, the same function a fiber cable performs underground.

SpaceX just forced Verizon, AT&T and T-Mobile to team up for the first time in history

Starmind, on the other hand, is something completely different, and tather than moving data, its satellites would compute data through artificial intelligence and directly in orbit using onboard processors powered by large solar arrays. Where a Starlink satellite is essentially a very fast pipe, a Starmind satellite is a server. The practical implication is that Starmind would allow AI models to run inference, process queries, and generate outputs from space, then beam results down to users anywhere on Earth within milliseconds, and without the data ever needing to travel to a terrestrial data center.

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Starship will be able to carry 30 to 50 AI1 satellites per launch, delivering the equivalent of dozens of server racks per flight, with no land acquisition, no power grid approval, and no cooling infrastructure required on the ground.

SpaceX is pursuing this new technology as terrestrial data centers are running into hard limits such as lack of physical space, community opposition, and power and water consumption at a scale that is increasingly difficult to permit. Space has unlimited solar power, natural vacuum cooling, and no zoning boards. Musk said in a June 8 video presentation that he expects space to become the lowest-cost location to deploy AI compute within two to three years. Two AI1 prototypes are scheduled to launch in early 2027, with volume production targeted for the end of that year at a new facility called Gigasat.

The real world applications Starmind enables extend well beyond powering Grok. A constellation of orbiting AI processors could run inference workloads for any paying customer, anywhere on Earth, with latency measured in milliseconds rather than the seconds associated with ground-based cloud routing across continents. Starmind, if it scales as described, would make SpaceX the landlord of AI compute the same way Starlink made it the landlord of satellite internet.

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Tesla pushes back against unfair reporting of accidents

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tesla
(Credit: Tesla)

Tesla is pushing back against the unfair reporting of accidents involving its vehicles. Many media outlets were quick to jump to conclusions about a fatal accident involving a Tesla in Katy, Texas, that happened recently.

The driver of the vehicle, which slammed into a brick house and killed a woman inside, stated the car was operating on Autopilot. Tesla CEO Elon Musk and Head of AI Ashok Elluswamy both challenged that claim, with Elluswamy revealing last night that the system was overridden by the driver, who pressed the accelerator pedal “all the way to 100%.”

Tesla finally clarifies fatal Texas crash, confirms driver manually overrode acceleration

The car reached a speed of 73 MPH during the crash, Elluswamy detailed, and stated that the accelerator pedal was even pressed after the crash.

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The story has been spread throughout the media with either incomplete or incorrect reporting, with some stories still not updated nearly 24 hours after Musk and Elluswamy posted answers about the crash on X.

The reporting has been a thorn in the side of Tesla for several years. Vehicle accidents involving Teslas are usually reported with the manufacturer’s name in the headline, while other companies are free of criticism when their cars are involved in accidents.

Here’s an example of that:

Many media outlets stated the car was in “self-driving mode” or “Autopilot mode” when the car crashed. The truth is, now that Tesla has chimed in, that the driver had manually overriden the system by pressing the accelerator. Elluswamy commented on the unfair reporting:

“This blatantly irresponsible reporting does more harm to people than they realize.

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Using Tesla self-driving is far safer than manual driving, and this was measured over 10B miles.

Planting such FUD in the minds of general public, who might not know the all the facts, might prevent them from using this technology that makes them safer.”

The damage these headlines do to Tesla and the self-driving car movement is unexplainable. Most people do not realize the safeguards that are in place with Tesla’s self-driving functions; many people who have used it know the car would never travel at that speed in a residential area, not even on the most aggressive “Mad Max” setting.

It is important to remember that Tesla Full Self-Driving is not autonomous, and the company never claimed it was. Drivers are still responsible for paying attention and remaining vigilant. They must be able to take over at all times.

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