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SpaceX is halfway done building the world’s largest rocket booster

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New photos of the SpaceX Starship program’s first Super Heavy confirm that the booster prototype – known as Booster Number 1 (BN1) and set to become the largest rocket booster ever built – is already halfway complete.

Set to be the world’s tallest, heaviest, and most powerful liquid rocket booster ever built, Super Heavy is expected to measure some 70 meters (~230 ft) tip to tail, weigh ~3700 metric tons fully fueled, and produce around 7500 metric tons (16.5 million lbf) of thrust at liftoff. Starship, the reusable upper stage and spacecraft SpaceX is busy prototyping and testing, is 40% shorter than Super Heavy and features less than a quarter as many Raptor engines, producing thrust roughly equivalent to Falcon 9’s first stage.

Aside from a three or four-ring engine section, every subsection of the first Super Heavy booster is complete and awaiting assembly. (NASASpaceflight – bocachicagal)

Super Heavy will be equivalent to almost ten Falcon 9s at full thrust and outclass every rocket ever built. However, the basic design of the booster is effectively the same as any other liquid-fueled rocket, opting for a tall and thin Falcon-style cylinder with a high aspect ratio and no exterior coating – just bare metal.

Super Heavy’s airframe is made up of two main propellant tanks joined by a “common dome” and capped at both ends with an interstage (the structure that mates the booster to Starship) and engine/skirt section (encloses the thrust dome, supports landing legs, and houses umbilical ports).

The Interplanetary Transport System (ITS), circa 2016. While heavily outdated, it still serves as a good representation of Super Heavy’s basic layout. (SpaceX)
Starship and Super Heavy, circa 2019. (SpaceX)

While Super Heavy is dramatically different from Starship by almost any measure, SpaceX has ensured that hardware commonality is as extensive as possible. Ultimately, with minor tweaks, that means that SpaceX can (in theory) build Super Heavy with the exact same tools and techniques it’s used to churn out Starship prototypes.

As of the end of this month, a flurry of public photos from local (and visiting) photographers have confirmed that Super Heavy booster BN1 is effectively halfway to completion and currently stands 18 steel rings tall. Aside from booster-specific layout changes, that 33-meter-tall (~105 ft) barrel section is virtually identical to a Starship’s 20-ring barrel section, lacking only conical nose section that caps them off.

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The bulk of Super Heavy BN1’s liquid oxygen (LOx) tank is lifted beside Starship SN10. (NASASpaceflight)

The 18-ring stack also guarantees that the current assembly is Super Heavy BN1’s liquid oxygen (LOx) tank and confirms that like ITS, BFR, Falcon 9, and other SpaceX rockets, Super Heavy’s LOx tank will sit above its fuel (methane) tank. Likely either 38 or 39 rings tall overall, it also indicates that BN1 is a ring away from half of its full height, leaving the integration of its strengthened methane tank, custom engine section, and skirt as the last major tasks standing between SpaceX and its first Super Heavy prototype.

Bearing attachment points for four Raptor engines and unfinished cutouts for four more, the first Super Heavy thrust dome appears to be complete and awaiting its sleeve of steel rings. (NASASpaceflight – bocachicagal)
Meanwhile, Super Heavy BN1’s common dome section appears to be ready to join the rest of its assembled LOx tank any day now. (NASASpaceflight – bocachicagal)

According to Elon Musk, SpaceX will likely hop BN1 if or when it passes initial cryogenic proof and static fire testing. If that goes according to plan, it’s unclear if BN1 can be converted for two-stage Starship launch attempts or if SpaceX will simply move on to BN2 (already under construction).

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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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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