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SpaceX’s first orbital-class Starship and Super Heavy to return to launch pad next week
CEO Elon Musk says that SpaceX could return the first orbital-class Starship prototype and its Super Heavy booster to the launch site after rolling the rockets back to the factory for finishing steps.
In response to a video of Super Heavy Booster 4 (B4) returning to the build site, Musk rather specifically stated that both Booster for and Starship 20 (S20) will return to the orbital launch pad on Monday, August 16th. SpaceX returned Ship 20 to its ‘high bay’ vertical integration facility mere hours after the Starship was stacked atop a Super Heavy booster (B4) for the first time ever on August 6th. For unknown reasons, perhaps due to high winds, Booster 4 spent another five days at the pad before SpaceX finally lifted it off the orbital launch mount and rolled it back to the high bay, where it took Ship 20’s place on August 11th.
Almost immediately after S20’s August 6th return, its six Raptor engines were removed to make way for an engine-less proof test campaign that Musk has now implied could start as early as next Monday. Mirroring S20, SpaceX also begin uninstalling Super Heavy Booster 4’s 29 Raptor engines the same day it returned to the high bay.
Around 12 hours after the process began, SpaceX appeared to have removed 14 (just shy of half) of Super Heavy B4’s Raptor engines – a pace almost as spectacular as their 12-18 hour installation a bit less than two weeks prior. Aside from making engine removal dramatically easier, Musk says that SpaceX moved Ship 20 and Booster 4 back to the build site to expedite some minor final integration work – namely “small plumbing and wiring.”
However, aside from Raptor removal, the most obvious and significant work ongoing since the pair’s return to the high bay is the process of inspecting Starship S20’s heat shield and repairing or replacing broken, chipped, and loose tiles. Not long after Ship 20 arrived back at the build site, workers in boom lifts began a seemingly arduous process of inspecting the Starship’s nose heat shield and marking – with colored tape – hundreds of tiles with cracks, chips, or other less visible issues.
After several days of inspections and hundreds of tiles marked, SpaceX finally began the process of removing off-nominal tiles early on August 12th. According to NASASpaceflight.com, that removal process is not particularly easy and can require the use of power tools to effectively cut tiles off their embedded mounting frames. Given the amount of force required, some level of care is also almost certainly needed to avoid damaging any adjacent tiles, which could quickly cause a minor misstep to exponentially spread. Nevertheless, a small team of SpaceX technicians seemingly managed to remove no less than several dozen (and maybe 100+) broken tiles in a few hours.
Up next, those removed tiles will need to be replaced. Still, it remains to be seen if SpaceX will choose to fully complete Starship S20’s “98% done” heat shield before sending the ship back to the launch site for proof and static fire testing. To a degree, putting Starship through a gauntlet of ground tests with a full heat shield installed would be an excellent test of the resilience of its thermal protection system to major thermal stresses from frosty steel skin and expansion/contraction during fueling, as well as violent vibrations during static fires.
However, Starship S20’s heat shield is already so close to completion that it might be only marginally less valuable to save time by testing the vehicle as soon as possible.
To an extent, Booster 4 is a much simpler case as Super Heavy needs to major thermal protection. However, according to Musk, some or all of Super Heavy’s 29 Raptor engines will need their own miniature thermal protection system – perhaps a flexible blanket-like enclosure not unlike what SpaceX uses to partially protect Falcon booster engines during reentry. It remains to be seen if Booster 4 will return to the launch site without engines for cryogenic proof testing or if SpaceX will install heat shielded Raptors before starting the first flightworthy Super Heavy’s first test campaign.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
