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SpaceX CEO Elon Musk updates schedule for first orbital Starship launch

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SpaceX CEO Elon Musk has presented the first significant update on the company’s Starship program since September 2019, offering a couple of new details about the status of the first orbital launch attempt of the largest and most powerful rocket ever built.

Unfortunately, above all else, the promised update was primarily a rehash of the broad-strokes vision of SpaceX’s Starship and Mars programs, as well as some basic details – most already known – about the rocket, its Raptor engines, and how it will be operated. Nonetheless, a large portion of the event was dedicated to audience questions, some of which actually extracted some specific details from the SpaceX CEO. Perhaps the single most important news: a rough but updated schedule for Starship’s first orbital test flight.

To be clear, a great many questions remain unanswered. Months after Starbase’s first orbital tank farm reached some degree of completion, SpaceX has yet to fill four main liquid methane (LCH4) tanks with even an ounce of fuel. Over the same period, the farm’s five liquid oxygen and nitrogen (LOx/LN2) tanks have been filled with thousands of tons of propellant and coolant. Why is still entirely unclear, save for speculation that SpaceX ran afoul of rudimentary methane storage regulations and is ever so slowly rectifying those errors with modifications. Without so much as a partially operational tank farm, SpaceX will be unable to attempt an orbital Starship launch, let alone start the process of qualifying a Super Heavy booster for flight with wet dress rehearsals (WDRs) and static fire tests.

Musk also failed to confirm or offer an educated guess as to which Starship and Super Heavy booster will support the first orbital test flight (OTF), whether the first OTF will truly reach orbit (rather than ‘just’ orbital velocity), and what will happen to Ship 20 and Booster 4 if – as a great deal of speculation suggests – they’ve fallen out of favor. If they’re to be replaced, it’s also unclear why that is or how long it might take to qualify a new ship and booster given that Super Heavy B4, for example, has yet to attempt a single static fire test a full six months after it first reached its full height.

Booster 4 and Ship 20 were first stacked in August 2021. (NASASpaceflight – bocachicagal)

Nonetheless, largely thanks to questions asked by members of the media, Musk did offer some valuable insight into Starship’s first orbital-class test flight. The SpaceX CEO says that he believes the Federal Aviation Administration (FAA) could complete an environmental assessment of Starbase as early as March. In the same presentation, Musk stated that SpaceX would “hopefully [complete environmental reviews] a couple months.” A lack of environmental approval has been the single most important bottleneck of orbital Starbase launch operations for months. The FAA originally anticipated that those reviews would be complete by the end of 2021 but recently delayed the estimated date of completion to the end of February 2022. Another delay from February to March (or later) has been expected for weeks.

It’s unclear how seamless the whole process will be but SpaceX will also need to receive an FAA license for orbital Starship launches after clearing environmental reviews. That could take days, weeks, months, or even a year or more. If SpaceX doesn’t receive a Finding Of No Significant Impact (FONSI) on its Starbase environmental assessment (EA) and instead has to complete a far more extensive Environmental Impact Statement (EIS), Starbase could be stuck in bureaucratic gridlock well into 2023 or even 2024.

Thankfully, Musk is extremely confident in SpaceX’s alternatives. In the event that Starbase becomes indefinitely unusable, SpaceX has already received full environmental approval to launch Starship out of Kennedy Space Center Pad 39A. The company has already begun the process of assembling a Starship launch and catch tower offsite and Musk believes that a Pad 39A Starship launch site could be brought online in just 6-8 months if SpaceX refocuses all of its Starship resources onto Florida.

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B4 and S20 were stacked for the second time in February 2022 after a few months of testing. (Richard Angle)

The CEO also says that SpaceX’s goal is to have the hardware needed for Starship’s first orbital test flight ready to launch around the same as regulatory approval is secured – “hopefully a couple months for both,” in Musk’s words. If Starship S20 and Booster 4 are still assigned to mission, that schedule is not difficult to believe. Starship has already completed virtually all of the ground testing needed to qualify it for flight, while – from the outside – Super Heavy has never looked more ready for static fire testing.

If SpaceX intends to use a different ship and booster, though, the company will have to cut the amount of time needed for final assembly and qualification testing by a factor of two or three relative to B4/S20. If the next ship and booster pair takes a similar amount of time as B4/S20, the hardware needed for Starship’s first orbital launch attempt might not be ready until August or September 2022. SpaceX will also need to build, test, qualify, and ship around three-dozen Raptor 2 engines, the production of which could singlehandedly take at least six or seven weeks at the current pace of production.

Ultimately, no matter where the cards currently in the air end up falling, it looks like SpaceX has an extremely busy – and hopefully fruitful – year of Starship development and testing ahead of it

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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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.

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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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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