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SpaceX could begin testing its Mars rocket in Texas by late 2018, early 2019

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On the heels of a successful wet dress rehearsal for Falcon Heavy, SpaceX’s President and COO Gwynne Shotwell spoke briefly about SpaceX for an aerospace conference located at Texas’ Academy of Medicine, Engineering & Science. Ars Technica’s senior spaceflight editor Eric Berger was in attendance and provided a rough outline of live tweets during the first group of presentations.

While the phrasing cannot provide absolute confirmation, Berger summarized a statement by Shotwell suggesting that SpaceX’s Boca Chica, Texas launch site, currently in the early stages of construction, could be ready to host “vehicle tests” as soon as late 2018, early 2019. At this point in time, based on comments from Shotwell and CEO Elon Musk, it can be reasonably assumed that SpaceX’s Texas launch facilities will be dedicated mainly to the company’s interplanetary colonization efforts, and will probably be tailored to support the testing and eventual launches of BFR/BFS.

After nine months of earnest construction and rehabilitation, SpaceX’s LC-40 pad was recently reactivated and has since supported two launches without any major hitches. At the same time, LC-39A in flux in order to support launches of SpaceX’s new Falcon Heavy rocket, the size of which required some concomitant upgrades to multiple ground systems. With both of those major tasks now effectively complete, SpaceX’s pad construction team is free to either refocus their efforts towards Boca Chica. Over the past several months, Boca Chica has seen a gradual but consistent level of development, mainly by way of unaffiliated SpaceX contractors. These changes have been dutifully tracked over the last several years on NASASpaceflight.com forums by a handful of friendly local residents interested in the changes coming to Boca Chica and Brownsville, Texas, a nearby town.

SpaceX’s Boca Chica facilities and STARGATE dishes (center-left) seen at sunset from the top of the giant crane garage. (anonymous Instagram user)

Most significantly, the last several months have seen three major developments. First and most prominently, a permanent facility called STARGATE externally appears complete and its two large radio communication dishes have been installed nearby. The STARGATE facility is a public-private partnership between the University of Texas at Brownsville (now part of University of Texas Rio Grande Valley) and SpaceX, with the academic components focusing on research that SpaceX undoubtedly has interest in: improved orbital spacecraft tracking and communications. Operationally, SpaceX will use the facilities to communicate with and operate its Crew Dragon spacecraft during launches, set to begin with an uncrewed demonstration mission as early as August 2018.

Second, an absolutely massive trolley crane appeared on SpaceX’s land and was eventually housed in an apparently purpose-built shed. The crane dwarfs anything currently used at SpaceX’s launch facilities and is almost certainly a custom-ordered piece of equipment, and thus would be both expensive and explicitly purposeful. What that purpose might be is currently unknown, but it is entirely plausible that the crane is intended to support initial testing (or even limited manufacturing) of SpaceX’s first BFS prototype rockets. This speculation has now been strengthened by Shotwell’s January 11 2018 comment on potential “vehicle tests” occurring at the site within a year or so, and also meshes with a presentation she gave in October 2017 at MIT. It also fits with Elon Musk’s 2017 IAC comments that BFR construction tooling and facilities were respectively already ordered and under construction.

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The boom of the giant crane seen in late 2017, parked at SpaceX’s Boca Chica facilities. (Reddit /u/ ticklestuff)

Third and last, the aforementioned SpaceX-following locals observed the early stages of a solar power install beginning on some of SpaceX’s Boca Chica land in late 2017, and also noted that at least some of its contractors were part of Tesla Solar. Plans and permits for solar power were acknowledged as far back as 2014, although at that point the contractor was Solar City (now a part of Tesla). A handful of months later, NASASpaceflight user and all-around awesome guy Nomadd has installed a webcam on a tall pole with a wonderful view of both the solar installation (now nearly completed) and STARGATE. The acre of solar panels can be expected to produce as much as half a megawatt (MW) at peak sun, likely more than enough to offset a considerable amount of the facilities’ electricity usage even after it begins to be see serious use.

 

Originally announced as an additional Falcon launch facility in 2014, Boca Chica has remained relatively dormant over the last three years, and it is truly exciting to see activity ramping up. There are admittedly significant barriers that will prevent SpaceX from effortlessly repurposing its Boca Chica pad for BFR, a much larger rocket. If SpaceX intends to do that, they will almost certainly need to pass a significantly updated FAA environmental impact review and account for any remediations that might be required. Still, that is a small ask for for Brownsville’s local government and Texas as a whole, both of which have clearly enjoyed and begun to benefit from SpaceX’s presence in the otherwise unknown area. SpaceX is unlikely to give up on Boca Chica in the near term, so long as Ms. Shotwell maintains her belief that it is effectively the perfect location for BFR launches.

Overall, Shotwell’s comments over the last several months and today in particular are increasingly encouraging, and things are likely to only speed up as 2018 progresses, allowing SpaceX to focus more and more of its expertise on BFR, BFS, and its South Texas testing and launch facilities.

Full disclosure: As Shotwell did not specify which vehicle or vehicles could be expected to begin testing in 2018/2019, it is possible that Falcon 9, not BFR, was the statement’s target. This article should be taken with a grain of salt, as it is educated speculation based upon public information from SpaceX executives and Texas contractors. Teslarati reached out to SpaceX for additional information, but the company was unable to comment further on Shotwell’s presentation at the moment.

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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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.

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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.

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.

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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.

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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.

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SpaceX Terafab rendering

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.

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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.

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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.

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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.

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