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SpaceX’s fourth Starship prototype has begun to take shape in Florida

In the center of this image, atop a newly-constructed metal-framework mount, is likely the first steel ring of Starship's Mk4 prototype. (John Winkopp - Seamore Holdings)

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SpaceX’s Florida Starship team appears to have taken the first step towards assembling Starship Mk4, the fourth full-scale prototype of the next-generation spaceship.

Although SpaceX’s Boca Chica, Texas Starship campus is undeniably in the lead with their first prototype, Starship Mk1, it appears that the company’s Florida campus is far ahead of Texas with their second Starship prototype.

At the moment, SpaceX has set up two separate Starship build teams in Florida and Texas with the intention of creating a sort of internal competition to see which group’s Starships are first to flight and first to orbit. For the most part, it’s assumed that this “competition” is less a fight to the finish line than it is an A/B test, a common software development practice in which separate teams pursue different methods of achieving the same goals.

In the likely event that SpaceX is performing a radical form of A/B testing with rocket prototypes, both teams are continuously sharing best-practices and lessons-learned as they work to find the best possible methods for fabricating hardware and assembling Starships. Nevertheless, in A/B testing, fundamentally different approaches also tend to result in development schedules and final products that are unique, even if the end results are similar.

In the context of Starship, this is exactly what can be observed at SpaceX’s Florida and Texas facilities. Similarities abound in the radical method of en plein air manufacturing being implemented, while the Starship Mk1 and Mk2 hardware being built and assembled are also relatively similar, even if they have some distinct characteristics.

For example, it’s been observed that Starship Mk2 has almost certainly been constructed out of steel rings that are significantly taller than those used to assemble Starship Mk1. Taller rings meant that Mk2 needed fewer overall rings to reach the same height as Mk1, a fact that likely contributed to the impressive speed with which SpaceX’s Florida team was able to stack and weld most of Starship Mk2’s aerostructure.

Star(ship)fleet

According to SpaceX CEO Elon Musk, those similarities (and slight differences) are likely to continue for at least several more generations of prototypes. At a September 28th presentation and update on Starship, Musk revealed his opinion that Starship could be ready for its first orbital test flight(s) as few as six months from then – sometime in Q2 2020, give or take. To get there, Musk estimated that at least 5-6 Starship prototypes would need to be built in the interim.

Starship Mk3 will be built in Texas – in fact, the first ‘seamless’ steel ring may have already been fabricated at SpaceX’s Boca Chica facilities. According to Musk, Starship Mk4 will be SpaceX Cocoa’s second prototype. Based on John Winkopp’s October 17th drone overview, it appears that SpaceX’s Florida team has mounted the first steel Starship Mk4 ring atop a new work mount, potentially marking the start of Starship Mk4 assembly.

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Although it’s unclear if this is a proof of concept or something more substantial, what could be the first seamless steel ring of Starship’s Mk3 prototype has already been bent into shape in Boca Chica, Texas. (NASASpaceflight – bocachicagal)

SpaceX’s Texas team has prepared at least one full-scale sample of a single-weld (‘seamless’) steel ring, perhaps the start of Mk1’s successor, Starship Mk3. Meanwhile, SpaceX Cocoa – seemingly at some kind of impasse with the final integration and assembly of Starship Mk2 – has churned out a huge number of similarly smooth steel rings, to the extent that Teslarati previously (and incorrectly) surmised that the first Super Heavy booster was being fabricated.

During Musk’s September 28th presentation, he effectively confirmed that the almost two-dozen steel rings hanging out on SpaceX’s Cocoa, Florida campus were almost certainly the beginnings of Starship Mk4. However, given the sheer number of rings present (23), the reality is that what could be the entirety of Starship Mk4’s cylindrical tank and thrust structure section is probably sitting outside in Florida, waiting to be stacked. Altogether, those 23 rings could reach a height of more than 40m (130 ft), potentially more than is actually needed for a Starship tank section.

Of note, it’s been observed that SpaceX’s Florida campus has begun stacking individual Mk4 rings into dual-ring assemblies, potentially halving the amount of welding that will have to be done once stacking begins in earnest. (John Winkopp – Seamore Holdings, LLC)

Last but not least, local photographer and spaceflight fan Jon Van Horne captured what looks like a new Starship tank dome in work at SpaceX’s prospective Kennedy Space Center (KSC) build site, known as Roberts Rd. Given that Starship Mk2 already has two domes installed and a third and final dome staged and ready for installation, this fourth dome is very likely the first for Starship Mk4.

https://twitter.com/therealjonvh/status/1183176543914336258

In short, SpaceX’s Florida team is probably weeks ahead of Boca Chica in the process of building a second full-scale Starship prototype. Of course, the ultimate winner of this mock competition isn’t Florida or Texas, it’s SpaceX’s Starship program as a whole.

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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 shows what Roadster drivers will see on screen before thruster activation

Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.

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The next generation Tesla Roadster’s touchscreen, shown in Tesla’s first official look at the car’s interface. (Credit: Tesla/X)

Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”

The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.

Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.

That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.

The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.

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The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.

Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.

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Tesla reveals Optimus Academy, where robots teach themselves

Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.

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Concept rendering of Tesla Optimus in mass production

Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”

The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.

Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.

The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.

Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.

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The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.

Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.

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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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