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SpaceX CEO Elon Musk teases Mars breakthroughs as Starship design radically changes

SpaceX's massive BFR mandrel, used to mold its composite tanks and structures. (SpaceX)

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During an interview with Axios, SpaceX CEO Elon Musk noted that he was “[really fired up about] a number of breakthroughs [SpaceX had recently made]” while being asked about his thoughts on the likelihood of him personally going to Mars (“70%”).

The minute-long teaser did not go much deeper but it certainly raises a number of questions (and hints at explanations) for a rapid-fire series of contradictory developments and changes to SpaceX’s BFR – since renamed to “Starship” and “Super Heavy” –  per a series of tweets from Musk over the last two weeks.

In a typical Muskian fashion, when Axios interviewers asked, “What is the likelihood that you personally will go to Mars?”, the CEO responded with an exact percentage – 70% – without skipping a beat. Musk also fervently and rather eloquently refuted the popular and harebrained idea that any SpaceX-enabled Mars colony would simply become “an escape hatch for the rich”. If the rich wanted Mars or lunar bases as “escape hatches”, there are dozens of multibillionaires that could singlehandedly fund Musk’s estimated $2-10B price tag for the completion of the entire BFR development program while still retaining 50-90% of their net worth.

Musk’s retort is worth reading in full.

Mike Allen: “[Mars] could be an escape hatch for rich people.”

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Elon Musk: “No! Your probability of dying on Mars is much higher than earth. Really the ad for going to Mars would be like Shackleton’s ad for going to the Antarctic. It’s gonna be hard. There’s a good chance of death, going in a little can through deep space. You might land successfully. Once you land successfully, you’ll be working nonstop to build the base. So, you know, not much time for leisure, and once you get there, even after doing all this, it’s a very harsh environment, so there’s a good chance you die there. We think you can come back but we’re not sure. Now, does that sound like an escape hatch for rich people?”

Getting to here is not a cheap endeavor and loans could help SpaceX pave the way. (SpaceX)

Back to BFR

While thoroughly entertaining, the most interesting aspect of this one-minute teaser was the approximate two seconds where Musk suggested that SpaceX had recently made several major breakthroughs in the context of BFR and Mars. What exactly those breakthroughs could be is entirely unclear, but the fact that Musk seemed positive about the recent developments and spoke of “breakthroughs” at all feels like an encouraging sign that the last two weeks of Musk’s chaotic announcements, updates, and abrupt cancellations are less indicative of program instability than they initially seemed to be.

Most notably, Musk appeared to announce and then completely cancel a sort of mini-spaceship that SpaceX was to base off of Falcon 9’s upper stage as a BFR spaceship technology demonstrator in less than two weeks. If realized, that mini-BFS would have reentered Earth’s atmosphere at orbital velocities to flight-test hypersonic fins and a new “ultra light” heat shield that will be (or would have been) critical for the overall success of BFS/Starship.

Ironically, in the middle of writing this article, Musk tweeted specifically about “fundamental” changes to the spaceship, leaving little more than the general appearance and propulsion systems unchanged. In essence, the design of BFS/Starship is now almost unrecognizable when compared with past iterations, at least from a perspective of the ship’s most critical systems.If Starship will not be built out of composites, then it’s possible that the multiple years SpaceX engineers and technicians have spent trying to develop large carbon composite propellant tanks (2016-present) and the time, energy, and capital put into those efforts will be almost entirely for naught if BFR pivots away from composite tanks.

 

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By all appearances, dozens of employees have spent the last year accepting delivery of $10-50M worth of custom-built composite tooling, setting it up, and building giant composite tank domes and segments. If composite tanks are no longer planned for the booster or spaceship, all that work may have been for nothing. Needless to say, we could certainly do for Musk’s proposed Reddit AMA – if not an entirely new BFR update event – to shed some light on the machinations behind these earthshaking programmatic changes.

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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

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Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

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Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Investor's Corner

Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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