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SpaceX completes vast Mr Steven arm upgrades for quadruple-sized net

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Scarcely 48 hours after they began, SpaceX technicians have already completed installation of all four of Falcon fairing recovery vessel Mr Steven’s new and dramatically larger arms, as well as eight giant struts. All that remains to be installed is an upgraded net, said by CEO Elon Musk to have four times the area of its predecessor.

Put simply, it’s difficult to express how large these upgraded arms really are, and photos still only give a partial sense of their scale. SpaceX technicians busy installing the new arms on July 10th nevertheless offer a fleeting appreciation of the true size of this new payload fairing recovery apparatus, which will hopefully see its first operational debut in just two weeks with a fairing recovery attempt after the Iridium-7 Falcon 9 mission, July 25th.

All arms on deck

While it’s difficult to estimate from photos alone, it appears that Mr Steven’s new arms are minimum of roughly 65 meters squared, assuming a square aspect ratio. In other words, the vessel’s next and newest net could have an area as large as 3600 square meters (~40,000 square feet, ~0.85 acres), easily more than quadruple the size of Mr Steven’s previous net. For comparison, the massive autonomous spaceport drone ships (ASDS) SpaceX often recovers its Falcon 9 and Heavy boosters aboard have a usable landing area of roughly 45,000 square feet, a little more than 10% larger than Mr Steven’s new net.

With these vast new arms, struts, and (soon enough) net, SpaceX is likely as close as they have ever been to successfully catching a Falcon 9 fairing, an achievement that would likely allow the company to begin reusing the large carbon fiber-composite shrouds almost immediately. Critically, although SpaceX appears to have begun attaching recovery hardware to both fairing halves in recent West Coast attempts, it remains to be seen whether Mr Steven’s new claw apparatus will be able to catch both halves, thus closing the gap on fairing recovery without necessitating the leasing and modification of perhaps three additional copies of the vessel.

Adding three recovery-critical ships (two for West Coast missions, two for East Coast missions) to SpaceX’s already massive blue-water fleet could significantly raise the operating costs of each recovery attempt, as well as generally adding considerable complexity to the orchestration of those fleets come launch time. Perhaps not. Still, if Mr Steven sees success with his 4Xed net and arms, chances are very good that SpaceX will lease and modify another Fast Supply Vessel – if they already haven’t done so – to provide the company’s higher-volume East Coast launch facilities with their own, dedicated fairing catcher. Mrs Steven awaits…

Zeroing in on Falcon fairings

Worth noting, SpaceX may have already halved the error margin officially advertised for the parafoil guidance units it procured from Canadian supplier MMIST, apparently missing Mr Steven by about 50 meters while MMIST suggests a 50% chance of successfully landing a payload in a 100-meter sphere. Given the significant expense likely incurred by designing, building, installing, and testing two distinct net and arm systems aboard Mr Steven, it’s safe to say that SpaceX engineers and technicians believe there is a very strong chance that the newest solution will successfully close the fairing recovery gap, said by CEO Elon Musk to be a rather literal 50 meters between the vessel’s old net and the unforgiving ocean surface.

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With an additional 30 meters (~100 feet) of reach in both axes, the new net alone may be able to shrink that error margin by ~60%. Perhaps the fact that it also appears to cover (and thus protect) Mr Steven’s wheelhouse will allow the vessel more leeway to aggressively maneuver as the fairing nears touchdown, providing that final 20-meter leap to slip his net under the fall halves.

In the meantime, we will ponder who exactly SpaceX is procuring a 40,000 square foot net from.

Incredibly, this artist rendering of a much larger net installed on Mr Steven was perhaps two or more times smaller than the solution now installed on the vessel. (Reese Wilson)

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers.

Teslarati   –   Instagram – Twitter

Tom Cross – Twitter

Pauline Acalin – Twitter

Eric Ralph – Twitter

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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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SpaceX just locked up a NASA record no other U.S. spacecraft can touch

SpaceX’s Crew-13 Dragon reached the ISS in under eight hours, and NASA confirmed a record.

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SpaceX now owns every spot on the list of the five fastest trips a U.S. spacecraft has ever made to the International Space Station, and its newest entry beat the old mark by more than four hours.

Crew Dragon Grace docked to the forward port of the station’s Harmony module at 7:05 p.m. ET on October 1, just 7 hours and 55 minutes after lifting off from Space Launch Complex 40 at Cape Canaveral. NASA confirmed the milestone in a space station blog update, writing that the flight “marked the fastest launch‑to‑docking of a U.S. spacecraft in the history of the International Space Station.”

The previous U.S. record also belonged to Dragon. SpaceX’s uncrewed CRS-31 cargo mission reached the station in a little over 12 hours in November 2024. The fastest crewed trip before last week was Crew-11, which took 14 hours and 43 minutes in August 2025, according to Space.com.

A post that Elon Musk reposted on Monday filled out the rest of the ranking. Behind Crew-13, CRS-31 and Crew-11 sit Axiom’s Ax-2 mission at 15 hours and 35 minutes and NASA’s Crew-4 at 15 hours and 44 minutes. All five flew on Dragon.

SpaceX turned a heralding moment for Starship into its greatest

Crew-13 carried NASA astronauts Jessica Watkins and Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and Roscosmos cosmonaut Sergey Teteryatnikov. NASA had projected a docking around 8 p.m. ET, as Teslarati reported the day before launch, and Dragon arrived nearly an hour early. Our launch day coverage noted that the flight was lined up to be the quickest Crew Dragon transit yet.

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The speed came from timing more than hardware. SpaceX’s Julianna Scheiman said the station “was in an opportune spot in space,” which let Dragon start closing the gap almost immediately after reaching orbit. “This is close to the fastest it could be,” she added. Most Crew Dragon flights still take close to a day, using a series of Draco thruster burns to raise and phase their orbit before arrival.

Dragon’s next job at the station is a departure. NASA said Monday it is targeting 8:05 a.m. ET on Wednesday, October 7, for Crew-12 to undock, setting up a splashdown off the coast of California around 11:34 a.m. on Thursday. Clearing that port makes room for CRS-35, a cargo Dragon carrying the final set of iROSA solar arrays.

Dragon remains NASA’s only operational ride to the station while Boeing’s Starliner stays grounded, and the agency recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification.

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Elon Musk teases TSMC as potential Terafab partner

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SpaceX Terafab rendering
SpaceX Terafab rendering

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.

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.

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Elon Musk’s Terafab project locks up massive new partner

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.

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Tesla reveals early Robotaxi charging strategy, showing scrappy DNA

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Credit: Tesla

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:

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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.

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.

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