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SpaceX rolls Super Heavy booster to orbital launch mount
For the third time in four months, SpaceX has rolled the first potentially flightworthy Super Heavy booster towards Starbase’s orbital launch mount.
Combined with a large crane – fitted with a jig solely used to lift boosters – moving to a spot just beside the booster, it’s clear that SpaceX is preparing to reinstall Super Heavy Booster 4 (B4) on the orbital launch mount. In the context of its unusual history, though, what happens next to the first more or less finished prototype of the largest rocket booster ever built is less clear.
After a shockingly quick assembly over the course of six summer weeks, Super Heavy Booster 4 rolled out of Starbase’s ‘high bay’ facility and headed to the nearby orbital launch complex, where it was installed on a custom ‘mount’ designed to support booster testing and orbital launches. It’s now clear that during that early August photo opportunity and fit test, Booster 4 was nowhere close to finished. Nor, apparently, was it anywhere close to complete one month later when it returned to the orbital pad for the second time after another few weeks of work back at the high bay.
Three months (almost 14 weeks or 100 days) after the Super Heavy prototype’s second trip to the pad, SpaceX has yet to attempt to put the booster through a single proof test. There also appears to be a significant amount of work left to finish installing external ‘aerocovers’ and a heat shield meant to enclose all 29 of its Raptor engines. In the three-year history of Starbase, there isn’t a single prototype of the roughly two-dozen SpaceX has built, tested, and even flown that’s spent even half as long as Super Heavy B4 between apparent structural completion and its first test. Perhaps the fact that Booster 4 is a first-of-its-kind pathfinder explains SpaceX’s uncharacteristic sluggishness or reluctance to actually test the rocket.
In every other instance, SpaceX’s approach to Starship development has been to move incredibly quickly, build a large number of prototypes, and rapidly test those prototypes – often resulting in catastrophic failures. Data is gathered from those failures (SN1, SN3, SN4, SN8, SN9, SN10, SN11, and half a dozen smaller test tanks serve as examples), changes are made, and then the new and improved prototypes that follow repeat the process until SpaceX arrives at a successful design.
Super Heavy B4’s circuitous path has been almost nothing like those of its predecessors. That could also be partly explained by the unavailability of a stand or facilities capable of truly proof testing a Super Heavy, which necessitates a supply of around 3200 tons (7M lb) of liquid nitrogen (LN2; for a cryogenic proof test with full tanks), another 3200 tons of a combination of liquid methane (LCH4) and oxygen (LOx), and the ability to ignite – and survive – as many as 29 to 33 Raptor engines. The suborbital stands SpaceX has used to proof Starships and even Super Heavy Booster 3 don’t even have half the storage capacity required to fully test a booster and the mounts and their surroundings would likely be catastrophically damaged or destroyed by the thrust and blast created by dozens of Raptors.
Still, SpaceX could have theoretically put Booster 4 through a partial cryoproof and maybe fired up as many as nine Raptors at once – not a replacement for full proof testing but still plenty to ensure Super Heavy’s structural integrity and gather invaluable data on clustered Raptor performance. Instead, of course, Super Heavy B4 has sat at Starbase’s former landing zone for more than three months while teams removed engines, reinstalled engines, half-installed a full Raptor heat shield; and installed two of six or seven ‘aerocovers’ needed to protect heat exchangers, racks of pressure vessels, and hydraulic systems installed on the booster’s aft.
This is all to say that from the outside looking in, Booster 4’s path towards testing and flight has been almost entirely different from that of any other Starship prototype. While still quick in comparison with other launch vehicle development programs, relative to other Starship and Super Heavy prototypes, the rate of B4 progress has been far slower – strongly implying that something is seriously wrong with the booster, that SpaceX no longer feels that partial testing is worth the effort, that finishing Booster 4 just hasn’t been a priority for several months, or some combination of the above.
What that ultimately means is that it’s almost impossible to predict what Super Heavy B4’s future holds beyond the clear evidence that SpaceX will soon reinstall to reinstall it on an orbital launch mount that’s much closer to completion than it was the last time B4 was installed. At this point, it’s just as likely that the booster’s third launch mount installation will just be another mechanical fit test, though the hope is that it will kick off full-scale pneumatic and cryogenic proof testing. It could even culminate in the static fire of some or all of its 29 Raptor engines, which have been installed for several months.
Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
Tesla is expanding its Robotaxi service hours by pushing the time back by one hour, keeping the ride-hailing service operational until 11 p.m., one hour later than previously.
CEO Elon Musk confirmed the change and offered a specific reason the expansion has been gradual: the system still needs to reliably avoid small pets that are difficult to see after dark, as they commonly blend into the color of the road, especially when they’re grey.
The latest adjustment restores only a fraction of the operating window the service once held. When paid Robotaxi rides began in Austin on June 22, 2025, vehicles ran from 6 a.m. to midnight.
In September 2025, Tesla lengthened the day to a 2 a.m. close, producing a 20-hour window that stayed in place for most of the following year. By early August of this year, the cutoff had already been pulled back; an August 26 update formalized hours of 6 a.m. to 10 p.m. across Austin and several other markets.
The October move to 11 p.m. therefore leaves the Austin day one hour shorter than the original launch schedule and three hours shorter than the 2025 peak.
Musk addressed the constraint directly after the announcement. “The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night,” he wrote. “Literally trying to avoid grey kittens on grey tarmac in the dark.”
Robotaxi operating hours moved from 10pm to 11pm.
The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night. Literally trying to avoid grey kittens on grey tarmac in the dark.
— Elon Musk (@elonmusk) October 3, 2026
The example points to a low-contrast perception problem in which a small animal can blend into the road surface under limited lighting.
Tesla’s vehicles rely on cameras and neural-network processing rather than lidar; Musk has previously argued that advanced vision software can extract useful information even in low light by analyzing photon counts, but the pet-detection case remains the stated limiter in later hours.
The modest schedule change arrives alongside faster growth in the purpose-built Cybercab fleet. Texas registration data tracked by observers showed the Austin Cybercab count rising sharply in recent weeks, reaching 169 vehicles after more than 100 were added in a short span.
Tesla has indicated that a broader shift toward 24-hour operation is tied to the upcoming FSD v15 software release expected this month on Robotaxi vehicles. Until that capability is validated for the edge cases Musk described, the company continues to add service time incrementally rather than jumping straight to overnight coverage.
The one-hour extension gives Austin riders a later option for evening trips while the underlying detection work continues.
Elon Musk teases TSMC as potential Terafab partner
Tesla reveals early Robotaxi charging strategy, showing scrappy DNA
