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Starship was never meant to lower SpaceX's annual launch cadence. (SpaceX) Starship was never meant to lower SpaceX's annual launch cadence. (SpaceX)

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SpaceX’s first Super Heavy hardware is already being built at Florida Starship campus

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Based on some basic analysis of recent photos of SpaceX’s East Coast Starship facility, situated in Cocoa, Florida, SpaceX has almost certainly begun fabricating and staging hardware that will eventually become part of the company’s first Super Heavy booster prototype.

This is by no means surprising but it does confirm the reasonable assumption that SpaceX is already working hard to ensure that the first Super Heavy booster(s) can be assembled as quickly as possible. Additionally, SpaceX appears to have started clearing brush in the process of preparing to transport the Florida orbital Starship prototype (“Mk2”) to SpaceX’s Pad 39A launch facilities, dozens of miles away.

Counting rings

The aforementioned “basic analysis” is more or less comprised of looking for and counting the massive steel rings that SpaceX has decided to build its Starships (and Super Heavy boosters) out of. By all appearances, SpaceX is doing nearly everything short of milling and preparing the raw materials (steel) internally. In Florida and Texas, giant rolls of stainless steel are delivered to the worksite by semi-truck, where SpaceX technicians prepare the rolls for sectioning (likely with a plasma torch or laser) and any necessary machining.

From this…
….to this. (NASASpaceflight – bocachicagal)

Intriguingly, SpaceX’s Texas and Florida teams are using different sizes of sheets – Florida has gone for taller segments while Texas uses rings that are a fair bit shorter ring, welding two rings together before installing each section on Starship. Florida’s rings are roughly 1.8m (6 ft; +/- 5%) tall.

In August alone, Cocoa has effectively doubled the height of the barrel section of its Mk2 orbital Starship prototype, jumping from 7-8 to 15 steel rings. The barrel section is now ~28m (90 ft) tall and Starship Mk2’s pointed nose section is still approximately 20-22m (65-70 ft) tall, adding up to a stacked height of 48-50m, approximately 10% shy of its final 55m (180 ft) height. Assuming that SpaceX hasn’t stretched Starship further since CEO Elon Musk’s September 2018 update, this leaves Starship Mk2 around 2-4 rings and a small nose cap shy of its full height (excluding legs).

https://twitter.com/therealjonvh/status/1160369758728073216

Super Heavy rising

This brings us to even more recent views of SpaceX’s Cocoa Starship facility, taken on August 15th by local pilot Brian (Twitter: @flying_briann). A video from the flight offers an uninterrupted ~360-degree overview of the site, including glimpses of a surprising number of staged steel rings that have completed initial welding and are waiting for stacking and integration.

Note the brush being cleared on the bottom left of the thumbnail as SpaceX prepares for the challenging task of moving Starship (and Super Heavy) all the way to Kennedy Space Center.

Two photos taken a bit less than two weeks ago provide a decent overview of SpaceX’s Cocoa facility. Of note, six staged rings are visible, as well as four additional rings in the form of two stacked sections of two rings. Those latter two sections (four rings) have since been stacked on Starship’s tank section, bringing it to its current 15-ring, ~28m height.

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Two photos from Brian’s overflights on July 31st and August 3rd show the current status of SpaceX’s Cocoa steel ring fabrication. Since then, the Starship has grown even taller, but many additional rings remain. (@flying_briann)

Despite the fact that Starship Mk2 appears to be just a few rings away from its final height, Brian’s August 15th overview revealed that no fewer than 11 additional rings (18m, 60 ft) are either staged or in the final stages of welding. Even if SpaceX has significantly stretched Starship over the last 10 or so months of design iteration, it seems exceedingly unlikely that Starship has grown by a full 10-12m (~20%).

Rather, these rings are probably the beginnings of SpaceX’s first Super Heavy booster prototype, a necessity before Starship can begin crucial orbital flight tests. Per the vehicle’s official 2018 specifications, Super Heavy will stand at least 63m (205 ft) tall before accounting for its landing legs/fins, requiring around 35 steel rings to complete its propellant tanks, interstage, and thrust structure.

Starship was never meant to lower SpaceX's annual launch cadence. (SpaceX)
Starship separates from its Super Heavy booster in this updated render. (SpaceX)

According to CEO Elon Musk, Super Heavy will likely perform its first flight tests with approximately 20 Raptor engines, eventually arriving at a full 31-37 engines depending on the configuration. Musk also believes that Starship could be ready for its first orbital flight tests as early as December 2019, implying that SpaceX’s first Super Heavy prototype(s) could be fully assembled as few as 4-5 months from now.

In reality, 2020 is far more likely for both milestones, but Musk is not exactly well-known for his conservative schedule estimates.

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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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Tesla VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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