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SpaceX prepares new Starship tank for explosive test after rapid construction

SpaceX is preparing for a potentially explosive Starship testing, this time featuring the unusual mini-tank pictured here on January 9th. (NASASpaceflight - bocachicagal)

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Over the last few weeks, SpaceX’s South Texas Starship team has been making progress at a pace unprecedented even for the famously agile rocket company and is moving full speed ahead to kick off a new series of explosive tests as early as this morning.

Ever since SpaceX’s original Starship Mk1 prototype spectacularly failed during a November 2019 pressure test, the company has been rapidly rearranging and modifying the development schedule for its next-generation full-reusable rocket. Be it a side effect or coincidence, SpaceX effectively began closing its Florida Starship factory a week after Mk1’s demise and even shipped some of its Florida-built Starship hardware to Texas in recent weeks. However, most of the Florida workforce (up to 80%) was reportedly redirected elsewhere in the company, avoiding layoffs.

Some portion may have even moved to Texas and joined SpaceX’s Starship Boca Chica facilities. Given just how aggressively SpaceX has been expanding its local facilities and preparing new hardware for the next round of improved Starship prototypes, it seems quite likely that the South Texas outpost did indeed receive an influx of skilled workers. Most recently, the company has demonstrated its rapidly growing expertise in the bizarre art of building steel rockets en plein air by fabricating and integrating new tank domes and steel rings and then shipping the curious contraption to its nearby launch site in a matter of weeks from start to finish.

Although it’s difficult to determine the chronology of every single part of the mysterious new tank, it’s fairly safe to say that work on its structure began less than a week before SpaceX CEO Elon Musk tweeted a surprise update, indicating on December 27th that he was in Boca Chica, Texas working all night on “Starship tank dome production”.

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In simple terms, the business half of SpaceX’s next-generation Starship upper stage and Super Heavy boosters are comprised of three main parts, shared by almost all launch vehicles. Both are rocket stages that must be as light as physically possible while supporting thousands of tons worth of supercool liquid oxygen and methane propellant. The majority of a simple rocket is ultimately a duo of cylindrical tanks capped by tank domes – also known as bulkheads. The bottom bulkhead of boosters and upper stages also serves as a mounting point for an engine section, where the vehicle’s rocket engines are attached to the rocket body in order to transfer their thrust throughout the rest of the structure.

SpaceX CEO Elon Musk says that Starship tank domes have turned out to be “the most difficult part of [the rocket’s] primary structure” to manufacture, thus explaining why he was apparently assisting the Boca Chica team all night on December 27th.

Starship Mk1 exploded on November 20th, 2019 during a nonflammable propellant loading test, a failure that unofficial videos have compellingly linked to the weld joint connecting the rocket’s upper tank dome to its cylindrical tank. That section of the rocket began leaking cryogenic propellant moments before the entire upper dome tore off the rest of the vehicle and launched hundreds of feet into the air.

All hail Baby Tank

In an apparent response to the unsatisfactory results of Starship Mk1’s manufacturing methods, SpaceX has rapidly initiated an already-planned upgrade of its Starship facilities and manufacturing methods in South Texas, taking delivery of a wealth of new tools over the last several weeks. Most recently, SpaceX’s latest step towards demonstrating that it has substantially improved manufacturing quality arrived in the form of a single propellant tank – the same diameter as Starship Mk1 but much shorter than any possible flight hardware.

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Quickly nicknamed Bopper (short for Baby Starhopper) by locals and close followers, the miniature Starship test article came together at a truly spectacular pace. Comprised of two single-weld steel rings and two brand new tank domes, it appears that all four of the components were nothing more than parts and steel stock less than three weeks ago. The first sign of activity came around December 19th, when technicians began placing pressed steel sections onto a bulkhead (dome) assembly jig – used to precisely hold the pieces in the right shape and place as they are welded together.

A number of new single-weld steel rings were produced in Texas in the final weeks of 2019, pictured here on December 19th. (NASASpaceflight – bocachicagal)
SpaceX technicians also began assembling the first of two Starship test tank (‘Bopper’) domes around December 19th. (NASASpaceflight – bocachicagal)
Perhaps just 20 days or less after work started on the baby Starship tank, SpaceX transported the new hardware – made up of two domes and two rings – to a nearby launch (and test) pad. (NASASpaceflight – bocachicagal)

Incredibly, aside from taking less than three weeks to go from miscellaneous parts to an assembled Starship tank delivered to the test site, SpaceX technicians appeared to finish stacking and welding its two halves (each a ring and a dome) perhaps a handful of hours before it was lifted onto a transporter and driven to the launch pad.

As of dawn, January 9th, the welds joining the two halves of the mini Starship tank were visibly incomplete and in-progress. Note the bright point and unfinished line near the center, indicative of active welding. (NASASpaceflight – bocachicagal)

Even for SpaceX, moving a prototype from factory to test site hours after its primary structure was welded together represents an almost unfathomably fast pace of work – truly unfathomable in traditional aerospace. Whether or not such a pace of work is smart, sustainable, or worth it remains to be seen, but SpaceX is nevertheless on track to pressure test its new mini Starship tank as early as this morning, potentially resulting in another spectacular overpressure event (i.e. explosion).

If the tank survives up to or beyond the pressures SpaceX has designed it to, it’s safe to say that the next full-scale Starship prototype could come together far sooner than almost anyone might have expected.

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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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Tesla Full Self-Driving v14.2.2.5 might be the most confusing release ever

With each Full Self-Driving release, I am realistic. I know some things are going to get better, and I know some things will regress slightly. However, these instances of improvements are relatively mild, as are the regressions. Yet, this version has shown me that it contains extremes of both.

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Credit: Tesla

Tesla Full Self-Driving v14.2.2.5 hit my car back on Valentine’s Day, February 14, and since I’ve had it, it has become, in my opinion, the most confusing release I’ve ever had.

With each Full Self-Driving release, I am realistic. I know some things are going to get better, and I know some things will regress slightly. However, these instances of improvements are relatively mild, as are the regressions. Yet, this version has shown me that it contains extremes of both.

It has been about three weeks of driving on v14.2.2.5; I’ve used it for nearly every mile traveled since it hit my car. I’ve taken short trips of 10 minutes or less, I’ve taken medium trips of an hour or less, and I’ve taken longer trips that are over 100 miles per leg and are over two hours of driving time one way.

These are my thoughts on it thus far:

Speed Profiles Are a Mixed Bag

Speed Profiles are something Tesla seems to tinker with quite frequently, and each version tends to show a drastic difference in how each one behaves compared to the previous version.

I do a vast majority of my FSD travel using Standard and Hurry modes, although in bad weather, I will scale it back to Chill, and when it’s a congested city on a weekend or during rush hour, I’ll throw it into Mad Max so it takes what it needs.

Early on, Speed Profiles really felt great. This is one of those really subjective parts of the FSD where someone might think one mode travels too quickly, whereas another person might see the identical performance as too slow or just right.

To me, I would like to see more consistency from release to release on them, but overall, things are pretty good. There are no real complaints on my end, as I had with previous releases.

In a past release, Mad Max traveled under the speed limit quite frequently, and I only had that experience because Hurry was acting the same way. I’ve had no instances of that with v14.2.2.5.

Strange Turn Signal Behavior

This is the first Full Self-Driving version where I’ve had so many weird things happen with the turn signals.

Two things come to mind: Using a turn signal on a sharp turn, and ignoring the navigation while putting the wrong turn signal on. I’ve encountered both things on v14.2.2.5.

On my way to the Supercharger, I take a road that has one semi-sharp right-hand turn with a driveway entrance right at the beginning of the turn.

Only recently, with the introduction of v14.2.2.5, have I had FSD put on the right turn signal when going around this turn. It’s obviously a minor issue, but it still happens, and it’s not standard practice:

When sharing this on X, I had Tesla fans (the ones who refuse to acknowledge that the company can make mistakes) tell me that it’s a “valid” behavior that would be taught to anyone who has been “professionally trained” to drive.

Apparently, if you complain about this turn signal, you are also claiming you know more than Tesla engineers…okay.

Nobody in their right mind has ever gone around a sharp turn when driving their car and put on a signal when continuing on the same road. You would put a left turn signal on to indicate you were turning into that driveway if that’s what your intention was.

Like I said, it’s a totally minor issue. However, it’s not really needed, and nor is it normal. If I were in the car with someone who was taking a simple turn on a road they were traveling, and they signaled because the turn was sharp, I’d be scratching my head.

I’ve also had three separate instances of the car completely ignoring the navigation and putting on a signal that is opposite to what the routing says. Really quite strange.

Parking Performance is Still Underwhelming

Parking has been a complaint of mine with FSD for a long time, so much so that it is pretty rare that I allow the vehicle to park itself. More often than not, it is because I want to pick a spot that is relatively isolated.

However, in the times I allow it to pull into a spot, it still does some pretty head-scratching things.

Recently, it tried to back into a spot that was ~60% covered in plowed snow. The snow was piled about six feet high in a Target parking lot.

Tesla ends Full Self-Driving purchase option in the U.S.

A few days later, it tried backing into a spot where someone failed the universal litmus test of returning their shopping cart. Both choices were baffling and required me to manually move the car to a different portion of the lot.

I used Autopark on both occasions, and it did a great job of getting into the spot. I notice that the parking performance when I manually choose the spot is much better than when the car does the entire parking process, meaning choosing the spot and parking in it.

It’s Doing Things (For Me) It’s Never Done Before

Two things that FSD has never done before, at least for me, are slow down in School Zones and avoid deer. The first is something I usually take over manually, and the second I surprisingly have not had to deal with yet.

I had my Tesla slow down at a school zone yesterday for the first time, traveling at 20 MPH and not 15 MPH as the sign suggested, but at the speed of other cars in the School Zone. This was impressive and the first time I experienced it.

I would like to see this more consistently, and I think School Zones should be one of those areas where, no matter what, FSD will only travel the speed limit.

Last night, FSD v14.2.2.5 recognized a deer in a roadside field and slowed down for it:

Navigation Still SUCKS

Navigation will be a complaint until Tesla proves it can fix it. For now, it’s just terrible.

It still has not figured out how to leave my neighborhood. I give it the opportunity to prove me wrong each time I leave my house, and it just can’t do it.

It always tries to go out of the primary entrance/exit of the neighborhood when the route needs to take me left, even though that exit is a right turn only. I always leave a voice prompt for Tesla about it.

It still picks incredibly baffling routes for simple navigation. It’s the one thing I still really want Tesla to fix.

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Investor's Corner

Tesla gets tip of the hat from major Wall Street firm on self-driving prowess

“Tesla is at the forefront of autonomous driving, supported by a camera-only approach that is technically harder but much cheaper than the multi-sensor systems widely used in the industry. This strategy should allow Tesla to scale more profitably compared to Robotaxi competitors, helped by a growing data engine from its existing fleet,” BoA wrote.

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Credit: Tesla

Tesla received a tip of the hat from major Wall Street firm Bank of America on Wednesday, as it reinitiated coverage on Tesla shares with a bullish stance that comes with a ‘Buy’ rating and a $460 price target.

In a new note that marks a sharp reversal from its neutral position earlier in 2025, the bank declared Tesla’s Full Self-Driving (FSD) technology the “leading consumer autonomy solution.”

Analysts highlighted Tesla’s camera-only architecture, known as Tesla Vision, as a strategic masterstroke. While technically more challenging than the multi-sensor setups favored by rivals, the vision-based approach is dramatically cheaper to produce and maintain.

This cost edge, combined with Tesla’s rapidly expanding real-world data engine, positions the company to scale robotaxis far more profitably than competitors, BofA argues in the new note:

“Tesla is at the forefront of autonomous driving, supported by a camera-only approach that is technically harder but much cheaper than the multi-sensor systems widely used in the industry. This strategy should allow Tesla to scale more profitably compared to Robotaxi competitors, helped by a growing data engine from its existing fleet.”

The bank now attributes roughly 52% of Tesla’s total valuation to its Robotaxi ambitions. It also flagged meaningful upside from the Optimus humanoid robot program and the fast-growing energy storage business, suggesting the auto segment’s recent headwinds, including expired incentives, are being eclipsed by these higher-margin opportunities.

Tesla’s own data underscores exactly why Wall Street is waking up to FSD’s potential. According to Tesla’s official safety reporting page, the FSD Supervised fleet has now surpassed 8.4 billion cumulative miles driven.

Tesla FSD (Supervised) fleet passes 8.4 billion cumulative miles

That total ballooned from just 6 million miles in 2021 to 80 million in 2022, 670 million in 2023, 2.25 billion in 2024, and a staggering 4.25 billion in 2025 alone. In the first 50 days of 2026, owners added another 1 billion miles — averaging more than 20 million miles per day.

This avalanche of real-world, camera-captured footage, much of it on complex city streets, gives Tesla an unmatched training dataset. Every mile feeds its neural networks, accelerating improvement cycles that lidar-dependent rivals simply cannot match at scale.

Tesla owners themselves will tell you the suite gets better with every release, bringing new features and improvements to its self-driving project.

The $460 target implies roughly 15 percent upside from recent trading levels around $400. While regulatory and safety hurdles remain, BofA’s endorsement signals growing institutional conviction that Tesla’s data advantage is not hype; it’s a tangible moat already delivering billions of miles of proof.

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Tesla to discuss expansion of Samsung AI6 production plans: report

Tesla has reportedly requested an additional 24,000 wafers per month, which would bring total production capacity to around 40,000 wafers if finalized.

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Tesla-Chips-HW3-1
Credit: Tom Cross

Tesla is reportedly discussing an expansion of its next-generation AI chip supply deal with Samsung Electronics. 

As per a report from Korean industry outlet The Elec, Tesla purchasing executives are reportedly scheduled to meet Samsung officials this week to negotiate additional production volume for the company’s upcoming AI6 chip.

Industry sources cited in the report stated that Tesla is pushing to increase the production volume of its AI6 chip, which will be manufactured using Samsung’s 2-nanometer process.

Tesla previously signed a long-term foundry agreement with Samsung covering AI6 production through December 31, 2033. The deal was reportedly valued at about 22.8 trillion won (roughly $16–17 billion).

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Under the existing agreement, Tesla secured approximately 16,000 wafers per month from the facility. The company has reportedly requested an additional 24,000 wafers per month, which would bring total production capacity to around 40,000 wafers if finalized.

Tesla purchasing executives are expected to discuss detailed supply terms during their visit to Samsung this week.

The AI6 chip is expected to support several Tesla technologies. Industry sources stated that the chip could be used for the company’s Full Self-Driving system, the Optimus humanoid robot, and Tesla’s internal AI data centers.

The report also indicated that AI6 clusters could replace the role previously planned for Tesla’s Dojo AI supercomputer. Instead of a single system, multiple AI6 chips would be combined into server-level clusters.

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Tesla’s semiconductor collaboration with Samsung dates back several years. Samsung participated in the design of Tesla’s HW3 (AI3) chip and manufactured it using a 14-nanometer process. The HW4 chip currently used in Tesla vehicles was also produced by Samsung using a 5-nanometer node.

Tesla previously planned to split production of its AI5 chip between Samsung and TSMC. However, the company reportedly chose Samsung as the primary partner for the newer AI6 chip.

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