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SpaceX's Elon Musk works through holidays on Starship's "most difficult part"

SpaceX CEO Elon Musk is working with the company's Boca Chica team to get Starship's "most difficult part" ready for flight. (NASASpaceflight - bocachicagal)

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SpaceX CEO Elon Musk says he has been working through the holidays at the company’s Boca Chica facilities to get Starship’s “most difficult part” ready for the next-generation spacecraft’s next prototype and flight tests.

Known as tank domes or bulkheads, Musk says that the hardware is the most difficult part of building and assembly Starship’s primary structure, referring to the steel engine section, tanks, and pointed nose that comprise most of the spaceship’s body. Starship’s primary structure must stand up to the rigors of all aspects of flight, including highly-pressurized propellant tanks, extreme G-forces during launches, orbital reentry, and more.

It was never officially determined whether the failure was intentional or not but during the first Starship prototype’s (Mk1) last test campaign, the vehicle experience an overpressure event while being filled with liquid oxygen or nitrogen. Localized to the weld connecting the upper tank dome to Starship’s cylindrical tank section, the dome essentially sheared off at the weld and launched hundreds of feet into the air, sending a shockwave through the vehicle that crumpled many of its steel structures as if they were aluminum foil.

It’s likely that Starship Mk1’s failure was an intentional overpressure event, meaning that SpaceX may have purposely pressed the vehicle’s tanks beyond their design limits to determine how structurally sound they were. What is less clear is whether the rocket burst before or after reaching its theoretical design limit.

For reference, SpaceX’s Falcon 9 rocket operates with its fuel and oxygen tanks pressurized to about 50 psi (3.5 atm) with localized pressures likely doubling or tripling near the bottom of both tanks during the first minute or two of launch. Some amateur back-of-the-envelope calculations from videos of Starship Mk1’s burst event suggest that it was pressurized to at least 60-75 psi (4-5 atm) at its upper tank dome, meaning that the pressure on its two lower domes and tank walls would have been even higher. If correct, those unofficial figures mean that Mk1 actually performed quite well considering the ramshackle facilities and unprecedentedly spartan methods used to fabricate and assemble it.

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As such, Musk likely considers Starship’s tank domes the “most difficult part of [its] primary structure” in large part because of how difficult it is to make giant propellant tank domes simultaneously light and strong. Musk has previously implied that Starship Mk1 was more 200 tons (450,000 lb) empty while the ultimate goal for the spacecraft’s empty weight is closer to 120 tons, and a large portion of that weight savings will likely have to come from making its tank domes as light as possible.

In line with that educated speculation, the last month or so of SpaceX’s Starship work in Boca Chica, Texas has been marked by a distinct focus on building tank domes. In fact, Musk himself tweeted that he had worked all night with SpaceX engineers in Boca Chica in a bid to get dome production ready for Starship’s Mk3 prototype, the first Super Heavy hardware, and many more rockets to come.

Prior to Musk’s tweet, a Starship tank dome was actually shipped all the way from Florida to Texas and arrived earlier this month. Meanwhile, technicians have been briskly building up an additional dome using what appears to be a different method of integration involving new parts. SpaceX is currently attempting to weld Starship’s tank domes together from several dozen pre-formed sheets of stainless steel.

The sheets of steel assembled into the dome Musk showed on December 27th likely arrived in Boca Chica on December 13th, implying that SpaceX has managed to complete the majority of the first dome prototype – using a new process – in barely two weeks.

New sections of a tank dome arrived on December 13th. (NASASpaceflight – bocachicagal)
Technicians lifted the dome Musk was working on on December 28th, implying that it is more or less structurally complete. (NASASpaceflight – bocachicagal)
Hours after lifting the newest dome, SpaceX began assembling the next one. (NASASpaceflight – bocachicagal)
Starship’s third Boca Chica tank dome was spotted in-work on December 28th. (NASASpaceflight – bocachicagal)

After SpaceX lifted the partially-completed dome off one of its custom assembly jigs, workers almost instantly began staging new sections of steel, beginning the process of integrating yet another tank dome – now likely the fourth on-site in Boca Chica. Meanwhile, at a nearby section of SpaceX’s Boca Chica production facilities, yet another dome was visible on the 28th. In short, SpaceX should soon have more than enough tank domes to complete the next Starship prototype – said to be a significantly improved and refined design compared to Mk1.

Known as Starship Mk3 (or Starship SN01), Musk says that the rocket – currently just a miscellaneous collection of separate parts – could (“hopefully”) be ready for its first flight as soon as February or March 2020.

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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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Elon Musk teases Tesla Optimus Gen 3 capabilities: ‘So many improvements’

If you thought Optimus Gen 2 was impressive, Tesla might have a surprise for you.

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Credit: Tesla Optimus | X

Elon Musk has teased that huge improvements are coming to Tesla’s Optimus humanoid robot, which is arguably the product that the company is developing with the most potential for everyday use by consumers and valuation increases from a financial perspective.

Optimus is still in the development stages, but Tesla has made great strides in its development over the past several years. It started as a simple idea that was unveiled with a human being in a spandex suit.

Tesla posts Optimus’ most impressive video demonstration yet

Just a few years later, Tesla has developed several humanoid robot prototypes that have made their way to influencers and have lent a helping hand around the company’s manufacturing facilities.

Tesla has already introduced two generations of Optimus, as the most recent release featured a vast number of improvements from the initial version.

The following is a list of things Tesla improved upon with Optimus Gen 2 compared to Gen 1:

  • Tesla introduced a weight reduction of roughly 22 pounds, improving efficiency and agility
  • Optimus Gen 2 had a walking speed that improved by 30 percent over Gen 1
  • Tesla developed more capable hands that had 22 degrees of freedom, double that of Gen 1. This improved object handling
  • Optimus Gen 2 had a 2-degree-of-freedom neck, as Gen 1’s was fixed
  • Tesla integrated actuators and sensors for better performance. This includes things like foot force/torque sensing, articulated toe sections that are close to human foot geometry for better balance and movement
  • Optimus Gen 2 has 28 degrees of overall freedom, improving flexibility from the first generation
  • Tesla’s Optimus Gen 2 can do more than Gen 1, and has shown improved motor control and precision, doing things like squats, yoga poses, dancing, and even poaching an egg

These changes essentially brought Tesla closer to what will be the Optimus version that makes it to production. The company has plans to start production for the public in 2026, but some units will be manufactured for internal use within its factories as soon as this year. Tesla has said it could scale to 100,000 units or more by next year.

Musk also revealed to Teslarati recently that the company is in the process of building the production line that will bring manufacturing rates of Optimus to that level.

However, there is another design of Optimus coming, and Musk says it will feature “so many improvements”:

Tesla has said that Optimus will have the capability to perform tedious and time-consuming tasks like folding laundry, babysitting, cooking, walking the dog, and plenty of other things. However, it will be super impressive to see it do things that require true coordination, like threading a needle, for example.

Musk did not hint toward any specific developments that Tesla will aim for with Optimus Gen 3, but the sky is the limit, especially as it will be performing some manufacturing tasks across its factories.

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Elon Musk slams Bloomberg’s shocking xAI cash burn claims

Musk stated that “Bloomberg is talking nonsense.”

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Credit: xAI/X

Elon Musk has forcefully rejected Bloomberg News’ claims that his artificial intelligence startup, xAI, is hemorrhaging $1 billion monthly. 

In a post on X, Musk stated that “Bloomberg is talking nonsense.” He also acknowledged an X user’s comment that people “really have no idea what’s at stake” with AI.

Bloomberg‘s Allegations and Musk’s Rebuttal

The Bloomberg News report painted a dire picture of xAI’s finances. Citing people reportedly familiar with the matter, the news outlet claimed that xAI burns $1 billion a month as costs for building advanced AI models outpaced the company’s limited revenues. 

Bloomberg alleged that xAI is planning to spend over half of a proposed $9.3 billion fundraising haul in three months, with a projected $13 billion loss in 2025. The report also claimed that of the $14 billion that xAI has raised since 2023, only $4 billion remained by Q1 2025. Even this amount, the news outlet alleged, will be nearly depleted in Q2.

xAI did not comment on Bloomberg‘s claims, though Elon Musk shared his thoughts on the matter on social media platform X. In response to an X user who quoted the publication’s article, Musk noted that “Bloomberg is talking nonsense.” Musk, however, did not provide further details as to why the publication’s report was fallacious.

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xAI’s Bright Horizon

Despite Bloomberg‘s claims, even the publication noted that xAI’s prospects are promising. The company, now merged with X, aims to leverage the platform’s vast data archives for model training, which could reduce costs compared to rivals like OpenAI. Tapping into X also allows xAI to access real-time information from users across the globe. 

xAI’s valuation reportedly soared to $80 billion by Q1 2025, up from $51 billion in 2024. The AI startup has attracted heavyweight investors such as Andreessen Horowitz, Sequoia Capital, and VY Capital so far, and optimistic projections point to profitability possibly being attained by 2027. This would be quite a feat for xAI as OpenAI, the AI startup’s biggest rival, is still looking at 2029 as the year it could become cash flow positive.

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xAI supercomputer faces lawsuit over air pollution concerns

NAACP & environmental groups are suing Elon Musk’s xAI over turbine emissions at its Colossus supercomputer site.

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xAI-supercomputer-memphis-environment-pushback
(Credit: xAI)

The xAI supercomputer, Colossus, faces a potential lawsuit from the NAACP and the Southern Environmental Law Center over pollution concerns tied to its gas-powered turbines. The facility has sparked debate over its environmental impact versus economic benefits.

The xAI data center has been operational since last year. The company used pollution-emitting turbines without an air permit, citing a 364-day exemption. Southern Environmental Law Center attorney Patrick Anderson disputed xAI’s exemption, stating: “there is no such exemption for turbines — and that regardless, it has now been more than 364 days.”

The groups issued a 60-day notice of intent to sue under the Clean Air Act, challenging xAI’s permit application under review by the Shelby County Health Department.

According to AP, critics argue the turbines emit smog, carbon dioxide, nitrogen oxides, and formaldehyde, worsening health risks in an area with cancer rates four times the national average.

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“The permit itself says emissions from the site ‘will be an area source for hazardous air pollutants,’” the Southern Environmental Law Center noted, alleging Clean Air Act violations.

Opponents claim xAI installed up to 35 turbines—exceeding the 15 requested—without community oversight, straining Memphis’s power grid.

xAI responded: “The temporary power generation units are operating in compliance with all applicable laws.”

The company highlighted its economic contributions, including billions in investments, millions in taxes, and hundreds of jobs. At an April community meeting, xAI’s Brent Mayo underscored that the “tax revenue will support vital programs like public safety, health, human services, education, firefighters, police, parks, and so much more.” He projected that xAI would generate over $100 million in tax revenue by next year. The company is also investing $35 million in a power substation and $80 million in a water recycling plant.

Additionally, xAI is transitioning to sustainable power, particularly Tesla Megapacks. It is actively working on demobilizing the gas turbines.

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“The temporary natural gas turbines that were being used to power the [xAI’s] Phase I GPUs prior to grid connection are now being demobilized and will be removed from the site over the next two months,” shared the Greater Memphis Chamber. xAI brought Tesla Megapack batteries and a 150-megawatt substation online earlier this year.

Despite xAI’s expansion to a second 1-million-square-foot site, the lawsuit threat underscores tensions between innovation and environmental justice.

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