SpaceX has confirmed that the two large propellant tanks now present at its Boca Chica, Texas facilities will likely to be the last major ground tanks needed to enable the first test flights of the upper stage of its next-gen BFR rocket, known as the Big Falcon Spaceship (BFS).
Expected to begin as soon as late 2019, SpaceX executives have recently reiterated plans for a campaign of hop tests for the first full-scale spaceship prototype, in which the ship will follow in the footsteps of its Falcon 9-based Grasshopper and F9R predecessors.
https://twitter.com/krgv_mike/status/1055748966619537408
In a comment provided to a number of local outlets, SpaceX Communications Specialist Sean Pitt stated this about the recent arrival of a second large propellant storage tank at the company’s prospective South Texas test and launch facilities.
“The ongoing construction of our launch pad in South Texas is proceeding well. SpaceX has now received the final major ground system tank needed to support initial test flights of the Big Falcon Spaceship.” – Sean Pitt, SpaceX
While there may have been some slight uncertainty before, this official statement confirms beyond the shadow of a doubt that SpaceX is actively and rapidly preparing its South Texas property for a future of BFR-related tests, spaceship hops, and perhaps even launches.
Same dance, different hops
Unlike Falcon 9’s Grasshopper and F9R reusability development programs, SpaceX’s BFS hop test campaign is likely going to be much more aggressive in order to gather real flight-test data on new technologies ranging from unfamiliar aerodynamic control surfaces (wings & fins vs. grid fins), all-composite propellant tanks (Falcon uses aluminum-lithium), a 9m-diameter vehicle versus Falcon’s 3.7m, a massive tiled heat-shield likely to require new forms of thermal protection, and entirely new regimes of flight (falling like a skydiver rather than Falcon 9’s javelin-style attitude) – to name just a handful.
To fully prove out or at least demonstrate those new technologies, BFS hop testing is likely to be better described as “flight testing”, whereby the spaceship launches vertically but focused primarily on regimes where horizontal velocity is far more important than vertical velocity.
“But by ‘hopper test,’ I mean it’ll go up several miles and then come down. The ship will – the ship is capable of a single stage to orbit if you fully load the tanks. So we’ll do flights of increasing complexity. We really want to test the heat shield material. So I think we’ll fly out, turn around, accelerate back real hard and come in hot to test the heat shield because we want to have a highly reusable heat shield that’s capable of absorbing the heat from interplanetary entry velocities, which is really tricky.” – CEO Elon Musk, October 2017
Focusing on the important things (for fully-reusable rockets)
SpaceX does has significant familiarity with the general style of testing expected to be used to prove out its next-gen spaceship, a major department from anything the company has yet built or flown. Updated in September 2018 by CEO Elon Musk, the craft’s most recent design iteration is reportedly quite close to being finalized. That near-final design prominently features a trio of new aft fins (two able to actuate as control surfaces), two forward canards, and an updated layout of seven Raptor engines.
Critically, SpaceX has decided to commonize BFR’s main propulsion, choosing to skip the performance benefits of a vacuum-optimized Raptor variant for the simplicity and expediency of exclusively using sea level Raptors on both the booster and spaceship. This decision is ultimately strategic and well-placed: rather than concerning early-stage development with the inclusion of a second major branch of onboard propulsion, the company’s engineers and technicians can place their focus almost entirely on a one-size-fits-all version of BFR with plenty of room for upgrades down the road.
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- BFS seen standing vertically on the pads of its tripod fins. (SpaceX)
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- (SpaceX)
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- A better view. (SpaceX)
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- BFR’s booster and spaceship separate a few minutes after launch. (SpaceX)
With a rocket as large as BFR and a sea level engine already as efficient as Raptor, the performance downgrade wrought by the initial removal of Raptor Vacuum (RVac) is scarcely more than a theoretical diversion. The specific performance numbers remain to be seen but will likely be greater than 100 metric tons (~220,000 lbs) to low Earth orbit (LEO). Past a certain point, however, the actual performance to LEO and beyond is almost irrelevant, at least from a perspective of individual launches. The paradigm SpaceX is clearly already interrogating is one where the cost of individual launches is so low relative to today’s expendable launch pricing ($5,000-20,000/kg to LEO) that it will almost be anachronistic to design or work with a single-launch-limit in mind, a limit that is just shy of a natural law in the spaceflight industries of today.
Because SpaceX has already demonstrated expertise in vertically launching, landing, and generally controlling large rockets, the main challenges faced with BFR are more operational than purely technical. To be clear, the technical challenges are still immense, but successfully solving those challenges by no means guarantees that the aircraft-like operational efficiency needed for BFR to succeed can or will be fully realized.
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- A gif of Raptor throttling over the course of a 90+ second static-fire test in McGregor, Texas. (SpaceX)
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- SpaceX’s subscale Raptor engine has completed more than 1200 seconds of testing in less than two years. (SpaceX)
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- A closeup of BFS’ nose section, featuring impressively varied tile-sizes, joining methods, and extremely precise curves on the interface between canard wings and the hull. (SpaceX)
In 2016, Musk pegged SpaceX’s cost goals for a BFR-style fully-reusable rocket at less than $1M per launch for booster and spaceship maintenance alone, or $3.3M per launch with amortization (paying for the debt/investment incurred to fund BFR’s development) and propellant estimates included. To realize those ambitious costs, SpaceX will effectively have to beat the expendable but similarly-sized Saturn V’s per-launch costs (~$700M) by a factor of 100 to 200 – more than two orders of magnitude – and SpaceX’s own Falcon 9 and Heavy launch costs (~$55M to $130M) by 20-50X.
To even approach those targets, SpaceX will need to learn how to launch Falcon and BFR near-autonomously with near-total and refurbishment-free reusability, while also developing and demonstrating orbital refueling capabilities that do not currently exist and rapidly maturing large-scale composite tankage and structures. None of those things require Raptor Vacuum.
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Investor's Corner
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.
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.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
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.
Investor's Corner
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.
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.
News
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.
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.
New drone video shows Tesla’s Optimus Factory reaching a turning point
Tesla and SpaceX take “Terafab” Trademark fight to Federal Court
