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SpaceX CEO Elon Musk teases next-gen Starlink satellites, Starship factories

The future of Starlink satellites and Starship manufacturing. (SpaceX)

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CEO Elon Musk has shared a slideshow from a recent SpaceX all-hands meeting, revealing the company’s current priorities, sources of pride, and the first official renders of a few future projects.

Falcon and Dragon

The last seven or so months have been a landmark period for SpaceX’s workhorse Falcon 9 rocket. For the first time ever, the company is actually matching or exceeding extremely lofty launch cadence targets publicly revealed by Musk earlier this year. In the first five months of 2022, SpaceX has completed 22 successful launches. In the last seven months, SpaceX has completed 30 launches. SpaceX also has at least five launches nominally planned for June, meaning that the company is on track to launch just over once per week in the first half of the year after Musk revealed a goal of 52-60 launches in 2022.

SpaceX’s Dragon spacecraft continue to excel, as well. Cargo Dragon is on the brink of its 26th space station cargo delivery, while Crew Dragon remains the United States’ only way to launch NASA astronauts to the International Space Station it spent tens of billions of dollars to help build. Crew Dragon’s private career is also off to an excellent start, with two all-private launches already down and a third and fourth planned in late 2022 and early 2023 on top of regular NASA transport missions.

Starlink

According to Musk’s slide deck, SpaceX’s Starlink satellite internet constellation has secured close to half a million customers in 32 countries two and a half years after operational satellite launches began. The constellation has almost 2400 working satellites in orbit, of which almost 1800 are operational. There’s a good chance that half of all active satellites will be owned and operated by SpaceX within the next few months. SpaceX has also delivered more than 15,000 Starlink dishes to war-torn Ukraine and announced its first airline connectivity partnerships within the last few months.

Lastly, the CEO published the first official renders of SpaceX’s next-generation Starlink V2.0 satellites and the massive Pez dispenser-style mechanism Starships will initially use to deploy the massive spacecraft in orbit. Based on the renders, SpaceX appears to have more or less upscaled its existing rectangular Starlink V1.x satellite design by a factor of two, producing a spacecraft that will measure about 7 x 3 meters (23 x 10 ft). Curiously, the Starlink dispenser and tiny payload ‘slot’ shown only appear to allow Starship to carry around 60 satellites, suggesting that the company will need to develop a different deployment method to achieve its ultimate goal of launching 110-120 satellites at once.

Ship 24’s Starlink ‘Pez dispenser’ slot is easily visible. (NASASpaceflight – bocachicagal)

Starship

Finally, on top of sharing the first photo of Raptor engine installation on Super Heavy Booster 7, which could support Starship’s first orbital launch attempt later this year, Musk also revealed the first official renders of a pair of next-generation Starship factories SpaceX has already begun building. In South Texas, SpaceX is both expanding its existing Starship factory and replacing the three main sprung structures (tents) where most pre-stacking work has been done for the last two years with a single massive, permanent building.

At a new and rapidly growing SpaceX facility located on NASA Kennedy Space Center property, the company is simultaneously building a second next-generation Starship factory to supply multiple planned Florida launch sites with their own Starships and Super Heavy boosters.

Raptor installation progress on Booster 7.
The future of Starbase Texas’ existing Starship factory.
Florida’s upcoming Starship factory (center and right).

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 Roadster event requires restricted airspace, and the FAA obliges

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Credit: @BLKMDL3/Twitter

The Federal Aviation Administration (FAA) has established a Temporary Flight Restriction over SpaceX’s McGregor, Texas, rocket development and test facility, a move widely viewed as preparation for Tesla’s October 1 Roadster reveal. The restriction took effect September 18 and runs through October 2.

NOTAM FDC 6/3825 covers a 1.5-nautical-mile radius around the site near Waco and extends from the surface to 10,000 feet above ground level. The FAA cited hazards under 14 CFR 91.137(a)(3) and barred aircraft and drones from the zone. Tesla’s invitation to reservation holders already placed the event in Waco, about 20 minutes from McGregor, making the timing and location more than coincidental.

What stands out is the altitude. Typical recent TFRs at McGregor for engine static fires and component tests have used far lower ceilings, often around 2,000 feet. Raising the limit to 10,000 feet is unusually high even compared with some Starbase restrictions and signals operations that go beyond a standard ground-level engine test.

That extra airspace has fueled speculation about the long-promised SpaceX Package for the Roadster. Elon Musk has described cold-gas thrusters that could deliver sub-one-second 0-60 times and, more dramatically, brief lift-off. Reports earlier this year indicated Tesla planned a remote-controlled demonstration at McGregor in which the car would leave the ground with no one inside; spectators kept hundreds of yards away because of the noise.

The 10,000-foot envelope would give operators a large safety buffer even if the vehicle only hovers a short distance.

Tesla has not confirmed a flight demo. The company has only used the phrase “Go for launch” and posted a teaser image of the car on what looks like a launch pad. The TFR itself mentions only hazards. Still, closing airspace this high and this close to the reveal date strongly suggests the event will include more than a static display.

Whether the Roadster actually hovers on October 1 remains to be seen. What is certain is that the FAA has cleared a large vertical slice of Texas sky for whatever Tesla and SpaceX intend to show. Reservation holders heading to Waco will be among the first to find out if the car can do more than drive.

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Elon Musk

Elon Musk drops a surprise update on Boring Company’s next big dig

Musk says Boring Company could shrink the Austin to San Antonio drive to just minutes.

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Elon Musk says The Boring Company is working on what he called “a simple, precursor Hyperloop” tunnel connecting Austin and San Antonio, targeting speeds above 200 mph and cutting a drive that can take up to two and a half hours down to a consistent under 30 minutes. Musk posted the idea on X Sunday, in a reply to a repost of an AI generated video imagining a science fiction future with human colonies on other worlds, which he shared with the line “This is the future we shall bring into being.”


The Boring Company’s own account picked up the idea in the same thread, adding a detail about how the trip would actually work: “Because Loop/Hyperloop is express (i.e. no intermediate stops), one could travel from an Austin parking lot to a favorite San Antonio restaurant in about 30 minutes. As long as they both have Loop stations.” That framing ties the proposed intercity link to the same station model the company already runs in Las Vegas, where riders enter the tunnel network through small, garage style stops rather than one central terminal.

This is not the company’s first run at the Austin to San Antonio corridor. Boring Company floated tunnels between the two cities as far back as 2021, and later competed for a separate San Antonio Loop project tied to the airport before that specific bid stalled. Pitches for tunnels in Chicago, Los Angeles, and a New York to Washington corridor have followed a similar pattern of big announcement without a shovel in the ground.

What is different this time is the balance sheet, especially since The Boring Company closed a 3 billion dollar funding round led by investors in the United Arab Emirates earlier this month at a valuation near 23 billion dollars, giving the tunneling company more capital to chase speculative projects than it had during its earlier Texas pitches. The company is also mid-build on two other intercity systems it has actually broken ground on, inc;luding a Nashville tunnel linking downtown to the airport, where a second boring machine finished commissioning in June, and its Las Vegas network, where the station count keeps climbing on paper faster than tunnels get dug.

That gap between announcement and execution is the reason to treat Sunday’s post as an opening bid rather than a project. A tunnel spanning roughly 80 miles between two metro areas, running at speeds Boring Company has not demonstrated over any real distance, would dwarf anything the company has built. For now, the Austin to San Antonio Hyperloop exists as a caption under an AI generated space video.

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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

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

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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