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SpaceX’s fourth Starship prototype has begun to take shape in Florida
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.
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.
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.
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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Tesla is using the vehicles’ internal microphones to improve build quality, Vice President of Engineering Lars Moravy revealed recently.
It’s no secret that Tesla is always finding ways to make its manufacturing operations more efficient, accurate, and valuable. Constantly trying to make its cars better, the company has never placed any restrictions on what it will do to improve everything from panel gaps to paint.
As Teslas have been driving autonomously on the property of the Gigafactory Texas plant for a while now, Moravy revealed to Herbert Ong in a new interview that cars rolling off production lines now autonomously navigate themselves through a bumps, squeaks, and rattles (BSR) portion of the line. This helps to identify any loose or improperly installed internal parts.
The cabin’s microphones, which are used for a variety of things in ownership, simultaneously monitor any noises inside the vehicle while it rolls through the BSR portion of the production line. Moravy actually revealed that Tesla is trying to build “Full Self-Hearing,” an AI system that will detect minor imperfections so they can be corrected before delivery.
It’s no secret that build quality is something that Tesla struggled with as it scaled to a fully massive production operation that manufactures over 1.6 million vehicles per year. However, in recent years, especially, there have not been as many complaints. Tesla has truly improved upon its build quality and paint quality over the past several years, especially in the U.S.
Tesla’s ‘megacasts’ are key to massive build quality improvements
While those improvements have been evident, there are still some complaints; no automaker is perfect with this. But this step will now ensure that every single car that rolls off the production lines at Gigafactory Texas will be void of any creaks, squeaks, or squeals when it leaves the factory.
This measure is one of the most unique we’ve seen in terms of a strategy to avoid build quality issues, but it is not exclusive to Tesla.
Ford uses acoustic analysis AI to find abnormalities in seat motors, climate control units, and other components. Suppliers and OEMs will also use microphone arrays or particle velocity sensors in end-of-line stations.
The full interview with Lars Moravy is available below:
🚨 If you’re a Tesla investor, this is one interview you don’t want to skip. The full video posted below.
Jeff Lutz @thejefflutz and I sat down with Tesla VP of Engineering Lars Moravy, and it was packed with insights!
A few of the biggest takeaways:
• Cybercab is expected to… pic.twitter.com/fhYSr2dCqP
— Herbert Ong (@herbertong) July 1, 2026
Investor's Corner
Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent
Tesla (NASDAQ: TSLA) beat Wall Street expectations of 406,000 vehicles delivered in Q2 by reporting 480,126 deliveries for the three months ending in June.
Tesla reported it delivered 467,762 Model 3 and Model Y units, while 12,364 Model S, Model X, and Cybertrucks switched hands during the quarter. The Model S and Model X were officially sunset this past quarter and will no longer be part of the company’s Production & Delivery reports moving forward.
🚨 BREAKING: Tesla delivered 480,126 vehicles in Q2, ANNIHILATING Wall Street expectations of 406,000. Production was reported at 451,758.
Deliveries:
Model 3/Y: 467,762
Other Models: 12,364Production:
Model 3/Y: 442,936
Other Models: 8,822 https://t.co/TTHwQAsKt8 pic.twitter.com/7qI4Zj6FE5— TESLARATI (@Teslarati) July 2, 2026
The quarter is a pleasant surprise and a good rebound from Q1, when Tesla slightly missed the Wall Street consensus of 365,645 cars by reporting 358,023 deliveries for the first three motnhs of the year.
Energy storage deployments also provided some strength in Tesla’s delivery report, hitting 13.5 GWh for Q2. This is a particular division of Tesla’s business that has been overwhelmingly robust over the past few years, truly being a strong point of the company’s overall model.
For the year, Tesla analysts still predict deliveries to trend in the 1.69 million unit region, a modest 3 to 5 percent increase from the 1.64 million cars the company delivered last year. Tesla will likely return to more sequential and noticeable year-over-year growth as the Cybercab project starts to ramp up considerably in the next few years.
Tesla has some other potential catalysts to spur vehicle deliveries, too. Not only is it expecting Cybercab to truly start making a change in the next few years, but other vehicles could be entering the company’s lineup.
Tesla sends production Cybercab with no steering wheel, pedals to on-road testing
The slightly longer Model Y L has been a highly speculated release candidate in the U.S. It has already done incredibly well in China, and U.S. buyers have been wanting slightly more interior space than the Model Y. Now that the Model X is gone, it is more needed than ever.
Q2 highlights a pretty stable automotive division within Tesla, and no true concerns arise from these figures, especially considering it managed to beat expectations convincingly.
Tesla CEO Elon Musk posted a photo of himself standing with the Optimus production team inside Tesla’s Fremont factory, arms crossed amid workers in hard hats and safety vests. The image captures a pivotal industrial shift: the same facility space once dedicated to building Tesla’s flagship Model S sedan and Model X SUV is now home to the company’s humanoid robot manufacturing line.
Walking the Optimus production line in Fremont pic.twitter.com/ABS0tuRibW
— Elon Musk (@elonmusk) July 1, 2026
Tesla’s Fremont Factory, acquired in 2010 from the former NUMMI joint venture between Toyota and GM, has been the company’s original U.S. manufacturing hub since Model S production began in 2012.
The Model X followed soon thereafter. These premium vehicles offered lower annual volumes, recently around 30,000 combined, compared to the high-volume Model 3 and Model Y lines that continue around the site. Over their combined run, the S and X accounted for roughly 610,000 units.
In late January 2026, during Tesla’s Q4 2025 earnings call, Elon Musk announced the end of Model S and Model X production in Q2 2026. The final vehicles rolled off the line in early May. Rather than retooling for another vehicle, Tesla chose to convert the dedicated S/X assembly area into a dedicated Optimus Gen 3 production line.
Model 3 and Y manufacturing remains unaffected. Tesla’s official Fremont Factory page now lists Optimus alongside the 3 and Y as core products.
The conversion was executed with remarkable speed. After production stopped, crews dismantled the existing vehicle line and installed entirely new modular equipment—including lines sourced from Germany and dozens of sub-lines for actuators, batteries, and other components—in roughly four months.
Musk described the timeline as “insanely fast,” noting it would be unprecedented for any other manufacturer. Initial Optimus output is expected to ramp slowly due to the robot’s roughly 10,000 unique parts and the brand-new production processes involved. The Fremont line targets an eventual capacity of 1 million Optimus units per year.
Tesla isn’t joking about building Optimus at an industrial scale: Here we go
Optimus Development Timeline
- August 19, 2021: Optimus (then called Tesla Bot) formally announced at Tesla’s first AI Day. A concept video showed a person in a suit demonstrating the vision for a general-purpose humanoid capable of dangerous, repetitive, or boring tasks using the same AI architecture as Full Self-Driving.
- 2022: Early prototypes displayed. At the second AI Day in September, semi-functional units demonstrated walking across a stage and basic arm movements
- 2023: September videos showed improved capabilities, including sorting colored blocks, precise limb awareness, and holding a Yoda pose.
- 2024-early 2025: Factory integration videos showed Optimus navigating workspaces and handling objects like battery cells.
- January 2026: Gen 3 mass-production activities began at Fremont, with reports of over 1,000 Gen 3 units already operating inside the factory for real-world learning and AI training
- April 2026: Musk confirms Optimus production on converted Fremont line would begin in late July or August 2026. The Gen 3 reveal, originally eyed for Q1, was pushed closer to production start. A second, much larger Optimus factory at Giga Texas is under construction, with volume production targeted for Summer 2027 and long-term capacity of 10 million units annually
- July 1, 2026: Musk’s on-site visit and team photo confirm the Optimus line is operational and the transition is actively progressing
Tesla positions Optimus as potentially its largest project ever, leveraging vertical integration, AI expertise, and car-like manufacturing know-how to scale humanoid robots first for its own factories and later for broader industrial and consumer use.
The Fremont conversion serves as a critical proving ground for this ambitious new chapter in Tesla’s already-rich history.
Tesla is using vehicle microphones to improve build quality: here’s how
Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent
