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SpaceX’s next Starship prototype is already closing in on its first tests

SpaceX technicians work to flip Starship SN4's last major subsection, a sign that its installation could be just a few days away. (NASASpaceflight - bocachicagal)

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Continuing a trend of massive steel rockets built in a matter of days and weeks instead of months, SpaceX’s next Starship prototype is already closing in on its first tests.

SpaceX’s newest vehicle is set to pick up where the third full-scale Starship prototype – coincidentally known as SN3 – left off after operator error lead to its premature destruction on April 3rd. Now a pile of scrap metal, that ship only made it partway through cryogenic proof testing when its upper tank – almost fully filled with chemically-neutral liquid nitrogen – toppled over and pulled the rest of the prototype with it. With (hopefully) improved test procedures, Starship SN4 is now set to carry that torch forward.

Following the late Starship SN1 and SN3 prototypes, SN4 is on track to be the third full-scale, functional Starship prototype built in a handful of weeks thanks to major factory upgrades SpaceX has completed in recent months. While the loss of any particular prototype is undoubtedly a setback each time it happens, such a high rate and (apparently) low cost of production means that no single failure should be a major disruption, allowing SpaceX to iterate incredibly quickly as it learns from a flurry of real-world tests.

On April 11th, SpaceX completed the second of either three or four total stacking milestones for Starship SN4, pushing the ship halfway (or more) towards completion. (NASASpaceflight – bocachicagal)

Like SN3, SpaceX’s next prototype will soon be fully stacked and transported down the road from the factory to a nearby launch and test facility, both situated directly on the South Texas Gulf Coast. Based on SN1 and SN3, SN4 could be just a week or so away from that transport milestone. SN3, for example, reached Starship SN4’s current state of assembly around March 20th. Eight days later, the vehicle was moved to the launch pad for its first tests.

Starship SN4 appears to be no more than a few days away from its final stacking milestone, pictured here with Starship SN3 on March 26th. (Elon Musk)

On April 12th, SpaceX technicians flipped Starship SN4’s aft-most section, doubling as a bottom dome of its liquid oxygen tank and a mounting point for three Raptor engines. Starship SN3 passed the same point around March 18th, just ten days before it was moved to the launch pad. Per SN3’s assembly schedule, it should be just 2-3 days before SpaceX wraps up Starship SN4’s engine section by adding another two rings, followed by the engine section’s integration with the rest of the rocket approximately 5-7 days from now.

Starship SN3’s thrust structure and aft dome was flipped on March 18th. (NASASpaceflight – bocachicagal)
Starship SN4’s own tweaked thrust structure and aft tank dome was flipped on April 12th. (NASASpaceflight – bocachicagal)

Based on Starship SN3’s behavior before a badly-designed test triggered the series of events that destroyed it, the ship appeared to be performing extremely well with its upper (methane) tank almost completely full of super-cool liquid nitrogen. If Starship SN4 does a similarly good job and makes it through the rest of the test that SN3 was unable to, SpaceX has three Raptors already tested and ready to go for their first triple-engine static fire ever.

At this point, those engines are simply waiting in a nearby hangar for a Starship prototype to be declared flight (or at least static fire) worthy. Even more excitingly, should both the engines and the Starship in question perform flawlessly during those tests, the first flights are expected to follow very soon after. Whether it’s able to summit that particular hurdle, Starship SN4’s current rate of production suggests that the ship will be ready to kick off testing later this month, perhaps less than three weeks after its predecessor kicked the bucket. Stay tuned!

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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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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