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SpaceX’s first orbital-class Super Heavy booster rejoins Starship at the launch pad

Super Heavy Booster 4 rolls to Starbase's orbital launch pad for the second time. (Starship Gazer)

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For the second time in five weeks, SpaceX has rolled Starship’s first orbital-class Super Heavy booster from its Starbase factory to the launch pad ahead of a challenging and multifaceted test campaign.

Deemed Super Heavy Booster 4 or B4, the 69m (~225 ft) tall rocket first rolled to the launch pad around August 3rd after SpaceX technicians fitted it with 29 Raptor engines in a single night. Followed by orbital-class Starship prototype S20 a few days later, the two stages of a Starship were stacked to their full height on August 6th, briefly creating the largest rocket ever assembled. Ship 20 was then quickly returned to the build site, where SpaceX workers completed an additional ~10 days of finishing touches – mainly focused on avionics wiring and secondary plumbing.

A week later, Booster 4 followed Ship 20 back to Starbase’s ‘high bay,’ where teams ultimately removed all 29 of its Raptor engines and spent the next four or so weeks performing similar final integration work. Now, after installing what looks like hundreds of feet of wiring, dozens of additional gas and fluid lines, compressed gas tanks, hydraulic ‘sleds’ SpaceX’s first flightworthy Super Heavy has once again returned to the launch site

A bit less than two weeks ago, SpaceX once again installed 29 Raptors on Booster 4. This time around, though, all of those engines are believed to be ready for flight – or, at minimum, static fire testing – after completing qualification testing at SpaceX’s Central Texas development facilities. Intriguingly, every one of Super Heavy’s outer ring of 20 ‘Raptor Boost’ engines is also expected to have its own small umbilical panel that will connect to the orbital launch pad’s ground systems.

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When Booster 4 was installed on the brand new orbital launch mount, most of those individual engine connectors had yet to be installed and it’s unclear if SpaceX was actually able to test the complex mechanisms before Super Heavy returned to the build site. This time, all 20 engine umbilical actuators have been installed on the launch mount and it’s safe to assume that those mechanisms will be tested extensively in the coming weeks.

These are actually believed to be individual Raptor Boost umbilical connectors.

That testing will be part of a much more involved test campaign. Namely, if SpaceX intends to test Super Heavy Booster 4 at the orbital launch site, any booster testing will simultaneously require the shakedown of the orbital pad’s extensive, custom-built tank farm and a wide range of other ground infrastructure that simply didn’t exist at the start of 2021. Booster 4 qualification is no less daunting, as no Super Heavy has ever been fully tested. Now in the midst of being scrapped in place at SpaceX’s suborbital test facilities, Super Heavy Booster 3 did complete a partial cryogenic proof test and a static fire with three Raptor engines, but SpaceX has never fully filled a Super Heavy with >3000 tons (~6.6M lb) of propellant and never static fired more than three Raptor engines simultaneously.

Super Heavy Booster 4 during its first installation on the orbital launch mount.

Perhaps the most uncertain part of Super Heavy Booster 4 qualification is its static fire test campaign. However SpaceX gets there, the final challenge will likely be igniting all 29 of B4’s Raptor engines – potentially producing up to ~5400 tons (11.9M lbf) of thrust, thus making Super Heavy the most powerful rocket booster ever tested.

Simultaneously, SpaceX also began reinstalling Raptors on Ship 20 – currently installed at Suborbital Pad B – ahead of the Starship’s first proof test(s) and static fire(s). Stay tuned for updates on SpaceX’s plans for testing the first orbital-class Starship and Super Heavy booster.

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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 just trademarked MEGAPOD: here’s what it is

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tesla showroom
(Credit: Tesla)

Tesla just trademarked ‘MEGAPOD’ with the United States Patent and Trademark Office (USPTO), its latest move in what seems to be a hint that the company is incredibly focused on its AI efforts and storage needs as compute increases.

The application carries serial number 99893717 and lists the applicant as Tesla, Inc., located at 1 Tesla Road, Austin, Texas 78725.

The filing remains in ‘live pending’ status, and it is a new application waiting for assignment to an examining attorney. It has not yet been published or registered.

According to the official goods and services description in the application, Tesla describes ‘MEGAPOD’ as:

“Modular data center hardware systems for artificial intelligence computing, comprised of computer servers, computer hardware for artificial intelligence processing, computer networking hardware, electrical power distribution units, and cooling systems, sold as a unit; self-contained modular computing hardware systems for artificial intelligence workloads; integrated computer hardware platforms for artificial intelligence computing, namely, enclosures containing computer hardware, power distribution hardware, and cooling hardware, sold as a unit; downloadable software for monitoring, managing, optimizing, and regulating modular artificial intelligence computing hardware systems.”

This description specifies complete, self-contained modular units that integrate servers and specialized AI processing hardware with networking components, power distribution, and cooling systems. It also includes associated downloadable software for oversight and optimization of these systems. The language emphasizes hardware sold “as a unit” and enclosures that combine the necessary elements for AI computing workloads.

Tesla has an established history of developing and commercializing modular hardware systems. Its Megapack product line, for example, consists of utility-scale battery energy storage systems designed as containerized units for grid applications. The MEGAPOD filing follows a similar pattern of protecting a name for modular, integrated hardware platforms, this time focused on artificial intelligence computing infrastructure.

This could be an early move, especially as Tesla did not have trademark rights to the word ‘Cybercab,’ the name of its self-driving, ride-hailing-focused vehicle.

Trademark applications of this type allow companies to secure priority rights to a name for defined categories of goods and services. The USPTO examines applications for compliance with legal requirements, including distinctiveness and absence of conflicts with prior marks. If the application proceeds successfully through examination, publication, and any opposition period, it could result in a federal trademark registration providing nationwide protection. This is what Tesla’s obvious intention is with ‘MEGAPOD.’

Public reports and analysis suggest MEGAPOD could represent modular, container-style AI computing pods designed for easy deployment. These would bundle servers, AI accelerators, power systems, and cooling into self-contained units suitable for distributed AI workloads. This approach aligns with Tesla’s announced AI compute strategy.

In March 2026, Elon Musk outlined plans for “Digital Optimus” (also referred to as Macrohard), a joint Tesla-xAI project for AI agents capable of handling complex digital tasks. The plans include running these agents on Tesla’s AI4 hardware in parked vehicles as well as dedicated compute units installed at Supercharger stations, which collectively offer substantial unused electrical capacity.

What is Digital Optimus? The new Tesla and xAI project explained

A modular hardware platform like the one described in the ‘MEGAPOD’ filing would support scalable, rapid deployment of such distributed compute resources. It could complement Tesla’s other AI infrastructure efforts, including the Dojo supercomputer used for training models and the development of AI systems for autonomous driving and robotics, by enabling edge or regional AI inference without reliance on traditional centralized data centers.

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SpaceX is launching a secret spacecraft that could change how things are made in space

SpaceX’s secret disk-shaped Starfall capsule is targeting a market no reentry vehicle has cracked.

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SpaceX is targeting Tuesday, June 23 for the first flight of Starfall, a reentry capsule the company has developed almost entirely in private. The Falcon 9 launch window opens at 6:43 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available the same time on June 24. SpaceX has made no public announcement about the vehicle, only providing launch details. Everything known about it has come through FAA and FCC regulatory filings.

What makes Starfall different starts with its shape. Rather than the traditional cone used by Dragon and every other cargo return capsule in operation, Starfall is a flat disk that measures roughly  10.2 feet (3.1 meters) wide and just 2.5 feet (0.75 meters) tall, and weighing 4,630 pounds (2,100 kg) and capable of returning up to 2,200 pounds (1,000 kilograms) of payload from orbit. The disk geometry maximizes structural efficiency and payload volume relative to mass, and the heat shield mechanically jettisons just before splashdown, allowing recovery teams to retrieve both the capsule and the shield separately from the Pacific Ocean.

The difference with Starfall from existing competitors, such as Varda Space Industries, which has largely built the orbital manufacturing market and returns heavy payloads per flight is that Starfall’s specification is roughly 30 times more per mission, and is designed to be mass-produced and launched on either Falcon 9 or Starship. That combination of volume and launch access is something no standalone startup can replicate, and it puts SpaceX in direct competition with the companies that currently pay it to reach orbit.

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The intended market is orbital manufacturing: pharmaceuticals, protein crystals, semiconductors, and advanced optical fiber that physically cannot be produced in the presence of gravity. FAA documents describe Starfall’s long-term purpose as building a “self-sustaining commercial in-space manufacturing market” and as a potential successor to the industrial capabilities of the International Space Station, which is set to retire in the late 2020s. Military rapid global cargo delivery is a parallel application under active discussion with the Pentagon.

The reason some industries seek manufacturing in space comes down to gravity. On Earth, gravity causes materials to settle, separate, and deform during production. In microgravity, those constraints disappear.

SpaceX’s already controls launch access, which means it currently functions as the landlord for every competitor in the orbital manufacturing return space. Starfall converts that landlord position into vertical ownership, and it would no longer just carry other companies’ capsules to orbit, but rather operate the capsule, own the return logistics, and capture the service revenue directly. Viewed alongside Starlink, Colossus, and the xAI merger, Starfall fits a consistent pattern: SpaceX identifying infrastructure layers that others depend on and moving to own them outright. Orbital manufacturing return is the next layer on that list.

If Tuesday’s reentry, parachute sequence, and recovery demonstration goes as planned, the second FAA-approved test flight follows. A successful pair of demos would position SpaceX to begin offering Starfall as a commercial service, likely first to pharmaceutical and materials science customers before scaling toward the military and broader manufacturing segments.

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Tesla Semi spotted with ground truth validation equipment as launch looms

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Credit: Tesla

The Tesla Semi was spotted mounted with ground truth validation equipment as the company nears its looming launch. The Semi is Tesla’s Class 8 all-electric truck, and has been utilized in its earlier stages by many companies like PepsiCo. and Frito-Lay, who have been using it in a pilot program.

The Semi was spotted in Sunnyvale, California, and sports a typical ground truth validation unit that Tesla routinely uses on its vehicles. Ground truth validation is essentially the process of training supervised algorithms to ensure they can perform reliably. Tesla typically performs this on vehicles that are being released soon:

The Semi being spotted with this type of validation rig is important because it means the company is working on solidifying a Full Self-Driving model for its commercial vehicle offering. This would be a massive development for not only Tesla but also the logistics industry as a whole.

There are strict regulations on driving hours for commercial truck drivers, and autonomy is a way to potentially combat these issues. FSD is already a widely effective way that owners of typical passenger vehicles take stress out of travel. Even launching a semi-autonomous platform for truck drivers to use to increase safety, reduce fatigue, and increase productivity would be a huge development.

Tesla Semi gets strange-but-understandable comparison from Jay Leno

The Semi has already proven to be an ideal solution for companies that use commercial logistics. It has increased efficiency and reduced operating costs for many companies that have been able to use it in pilot programs.

There are expected to be some bumps along the way. Tesla saw some challenges with FSD on the Cybertruck, as it had never had a vehicle with cameras at that height, so some of the features with FSD were not immediately available. Just a week ago, Tesla launched Actually Smart Summon (ASS) for Cybertruck, nearly three years after the vehicle was first delivered to customers.

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