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SpaceX begins assembling first orbital Starship and Super Heavy booster

Starship S20 entered the assembly or 'stacking' phase on July 3rd. (NASASpaceflight - bocachicagal)

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SpaceX has begun rapidly assembling the first orbital Starship prototype and the Super Heavy booster set to launch it isn’t far behind.

SpaceX’s Boca Chica, Texas rocket factory seemingly turned a corner in early July as sections of Starship 20 (S20) began to pop up around the site. Though parts labeled Starship “SN20” first appeared as far back as March 2021, the only unequivocal work on SpaceX’s first purportedly orbital-class Starship began in mid-June with the integration of the first engine section with mounts for six – not three – Raptors.

However, in line with SpaceX’s strict focus on maximizing the speed of Starship development and shortening the path to orbit, the company has frequently built Starship hardware before firmly assigning that hardware to any given ship, booster, or tank. In other words, until SpaceX actually begins stacking multiple completed rocket sections, there’s always a degree of uncertainty about the fate of any given ring, dome, or tank barrel. With Starship S20, that process began earlier this month and Super Heavy Booster 4 is likely to follow suit within the next few days – if it hasn’t already.

Since SpaceX unceremoniously rolled Starship prototype SN16 to an empty lot in mid-May, the company didn’t stack a single Starship part until the first week of July – unusual after a frenetic seven months spent building, qualifying, and launching Starships SN8, SN9, SN10, SN11, and SN15 and testing test tanks SN7.2 and BN2.1. Around the same time as Starship SN15 became the first prototype to successfully complete a high-altitude test flight and land in one piece, news broke that SpaceX was striving to perform Starship’s first orbital test flight with Ship 20 (S20) and Booster 3 (B3) as early as July.

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Eventually, Booster 3’s orbital launch assignment shifted to Booster 4 as it became clear that the former prototype wasn’t meant to fly, but Starship S20 remained. More likely than not, the almost two-month gap between Starship SN16’s instant retirement and the start of the next flightworthy prototype’s assembly can be explained by the significant changes, upgrades, and undecided design decisions required to jump to S20.

Beyond the need for a thrust structure capable of supporting three sea-level Raptors and three vacuum-optimized engines, Starship S20 would need a full heat shield with thousands of tiles; orbital-class communications and avionics; and the general polished fit and finish required for an orbital launch attempt to have a good shot at producing the data needed for it to be valuable. SpaceX appeared to conclude that those stars were aligned in early July.

Starship S20 entered the assembly or ‘stacking’ phase on July 3rd. (NASASpaceflight – bocachicagal)
S20’s forward dome section was likely installed on July 13th. (NASASpaceflight – bocachicagal)
Later the same day, S20’s aft engine section and leg skirt were mated. (NASASpaceflight – bocachicagal)

Two weeks after the first stack, Starship S20 is already approximately half-assembled and the last section of the vehicle’s tanks is almost ready for installation. What could be Starship S20’s nosecone is also in the late stages of assembly, though SpaceX has yet to even attempt to fully cover a nose in heat shield tiles and getting that process right could take an attempt or two.

Booster 4 rings are pictured here on the bottom and right. (NASASpaceflight – bocachicagal)

Meanwhile, as evidenced by the booster common dome section hanging in midair in the image above, the assembly of Super Heavy booster 4 (B4) – the same booster tasked with supporting Starship’s first orbital launch attempt – may have begun on July 15th. If the Super Heavy common dome assembly was simply being moved relocated, a separate four-ring section has been staged outside of the high bay to kick off Booster 4 stacking within the next few days.

All told, it’s not inconceivable that both of the first orbital-class Starship and Super Heavy prototypes will be fully assembled and ready for testing – integrated or otherwise – sometime in August.

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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 influencers argue company’s polarizing Full Self-Driving transfer decision

Tesla maintains it will honor transfers for orders with initial delivery windows before the deadline and offers full deposit refunds otherwise, citing longstanding fine print that the program is “subject to change at any time.”

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Tesla’s decision to tighten its Full Self-Driving (FSD) transfer promotion has ignited fierce debate among owners and enthusiasts.

The company quietly updated its terms in late February 2026, changing the eligibility from “order by March 31, 2026” to “take delivery by March 31, 2026.”

What began as a flexible incentive to boost sales, allowing buyers to transfer their paid FSD (Supervised) to a new vehicle, now excludes many, particularly Cybertruck owners facing delivery delays into summer or later.

Tesla maintains it will honor transfers for orders with initial delivery windows before the deadline and offers full deposit refunds otherwise, citing longstanding fine print that the program is “subject to change at any time.”

The reversal has polarized the Tesla community, with accusations of a “bait-and-switch” clashing against defenses of corporate pragmatism. Many owners who placed orders under the original wording feel betrayed, especially as production backlogs and new unsupervised FSD rollout complicate timelines.

However, Tesla has allowed them to cancel their orders and receive a refund.

Critics of the decision argue that the change disadvantages loyal customers who helped fund FSD development, calling it poor communication and a revenue grab as Tesla pivots toward subscriptions.

Popular influencers have amplified the divide. Whole Mars Catalog struck a measured but firm tone, acknowledging the original “order by” language but emphasizing Tesla’s right to adjust terms. He has continued to defend Tesla in this particular issue:

He criticized extreme backlash as “dramatization” and “spoiled kids,” noting the unsupervised FSD era and broader sales challenges make blanket transfers financially risky. Whole Mars advocated for polite outreach to CEO Elon Musk over the issue.

In a contrasting perspective, Dirty TesLA voiced sharper frustration, posting that blocking transfers feels “crazy” and distancing himself from “people that want to worship a corporation and say they can do no wrong.” His stance resonated with owners who view the policy flip as disrespectful to early adopters.

Popular Tesla influencer Sawyer Merritt captured the frustration felt by thousands. In a widely shared thread viewed over 700,000 times, Merritt detailed how pre-change Cybertruck orders now risk losing FSD eligibility unless their initial delivery window falls before March 31.

The controversy underscores deeper tensions—between Tesla’s need for revenue discipline and owners’ expectations of goodwill. As FSD evolves toward unsupervised capability, the community remains split: some see the change as necessary business, others as a broken promise. Whether Tesla reconsiders under pressure or holds firm remains to be seen, but it does not appear they are planning to budge.

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Tesla Semi’s latest adoptee will likely encourage more of the same

Public visibility matters. When shoppers see a trusted name like Ralph’s running clean, high-tech trucks on public roads, skepticism fades. Competitors such as Albertsons, which pre-ordered Semis years ago, and other chains chasing ESG targets now have proof that electric autonomy works in real-world grocery fleets.

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Credit: X | ChargePozitive

The latest adoptee of the Tesla Semi will likely encourage more businesses in the same realm to adopt the all-electric Class 8 truck, as a new company utilizing the Semi has been spotted in Southern California.

A sleek, futuristic Tesla Semi truck branded for Ralph’s Supermarkets was spotted cruising a Los Angeles highway in a viral 13-second dashcam video posted March 2, by X user ChargePozitive.

This sighting confirms Kroger’s March 2025 partnership with Tesla to deploy up to 500 autonomous electric Semis.

While the initial announcement targeted Midwest supply chains, the California appearance under the Ralph’s banner shows the program expanding to Kroger’s West Coast operations. Ralph’s, a staple for millions of Southern California shoppers, is now hauling groceries with the Semi, which has zero tailpipe emissions and claims up to 500 miles of range per charge.

Tesla Semi pricing revealed after company uncovers trim levels

The timing could not be better for sustainable logistics. Traditional trucking accounts for a massive share of retail emissions, but Tesla’s Semi slashes fuel and maintenance costs while leveraging full autonomy to ease driver shortages and improve safety.

Tesla’s expanding Megacharger network, including new sites along major freight corridors and partnerships like the recently-announced one with Pilot Travel Centers, is removing range anxiety and making nationwide scaling realistic. There’s still a long way to go, but things are moving in the right direction.

Public visibility matters. When shoppers see a trusted name like Ralph’s running clean, high-tech trucks on public roads, skepticism fades. Competitors such as Albertsons, which pre-ordered Semis years ago, and other chains chasing ESG targets now have proof that electric autonomy works in real-world grocery fleets.

PepsiCo’s successful pilots already demonstrated viability, and Ralph’s sighting adds retail credibility.

As Tesla ramps high-volume Semi production through 2026, this isn’t an isolated curiosity. Instead, it’s a catalyst. More grocers adopting the platform will accelerate industry-wide decarbonization, cut operating expenses, and deliver tangible environmental wins.

The future of sustainable supply chains is already on the highway, and Ralph’s just made it impossible to ignore.

Moving forward, Tesla hopes to expand the Semi program into other regions, including Europe, which CEO Elon Musk recently said is a total possibility next year.

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Tesla ramps Cybercab test manufacturing ahead of mass production

Tesla still has plans for volume production, which remains between four and eight weeks away, aligning with Musk’s statements that early ramps would be deliberately measured given the Cybercab’s novel architecture and full reliance on Tesla’s vision-based Full Self-Driving technology.

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Credit: Joe Tegtmeyer | X

Tesla is seemingly ramping Cybercab test manufacturing ahead of mass production, which is scheduled to begin next month, the company said.

At Tesla’s Gigafactory Texas, production of the Cybercab, the company’s groundbreaking purpose-built Robotaxi vehicle, is accelerating markedly. Drone footage from Joe Tegtmeyer captured striking aerial footage today, revealing what appears to be the largest public sighting of Cyebrcabs to date.

A total of 25 units were observed by Tegtmeyer across the Gigafactory Texas property, marking a clear step-up in testing and validation activities as Tesla prepares for a broader output.

Tesla Cybercab production begins: The end of car ownership as we know it?

In the footage, 14 metallic gold Cybercabs were parked in a tight formation outside the factory exit, showcasing their sleek, autonomous-only design with no steering wheels, pedals, or traditional controls. Another 9 units sat at the crash testing facility, likely undergoing structural and safety validations, while two more appeared at the west end-of-line area for final checks.

Tegtmeyer noted additional Cybercabs driving around the complex, hinting at active movement and real-world testing beyond static parking.

This surge follows the first production Cybercab rolling off the line in mid-February 2026, several weeks ahead of the originally anticipated April start.

That milestone, celebrated by Tesla employees and confirmed by CEO Elon Musk, kicked off low-volume builds on the dedicated “unboxed” manufacturing line, a modular process designed to slash costs, reduce factory footprint, and enable faster assembly compared to conventional methods.

Industry observers interpret the jump to dozens of visible units in early March as evidence that Tesla has transitioned into higher-volume test manufacturing.

Tesla still has plans for volume production, which remains between four and eight weeks away, aligning with Musk’s statements that early ramps would be deliberately measured given the Cybercab’s novel architecture and full reliance on Tesla’s vision-based Full Self-Driving technology.

The Cybercab, envisioned as a sub-$30,000 autonomous two-seater for robotaxi fleets, represents Tesla’s bold pivot toward scalable autonomy and robotics.

Tesla fans and enthusiasts on X praised the imagery, with many expressing excitement over the visible progress toward deployment. While challenges remain, including software maturity, regulatory hurdles, and supply chain scaling, the increased factory activity underscores Tesla’s momentum in turning the Cybercab vision into reality.

As Giga Texas continues expanding and refining the manufacturing process of the Cybercab, the coming months will prove to be a pivotal time in determining how quickly this revolutionary vehicle reaches roads in the U.S. and internationally.

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