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SpaceX resurrects California Starship factory plan just one year after abandoning it

Less than a year after SpaceX scrapped major plans for a Port of LA factory, the company is again in talks to build Starship hardware at the port. (Pauline Acalin)

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Just nine months after scrapping temporary Starship facilities built at a Los Angeles port, the company has unexpectedly reconsidered that decision, restarting talks to build a steel Starship factory in California.

In March 2018, nearly two years ago, the public first became aware of SpaceX’s plans to build a Starship factory in Port of Los Angeles. Begun while Starship was still known as BFR (Big Falcon Rocket) and designed to be built almost entirely out of carbon-fiber composites, the company’s first in-house effort to build its next-generation rocket began in an unassuming tent erected on port property around December 2017. Unintentionally foreshadowing the future of both Tesla Model 3 and SpaceX Starship production, that temporary tent was completed in just a month or two and officially began supporting BFR prototype production in April 2018.

In December 2018, CEO Elon Musk rebranded BFR as Starship and revealed that SpaceX would take the extraordinary step of redesigning the fully-reusable rocket to use stainless steel instead of carbon fiber. One year after SpaceX began building carbon fiber hardware, Musk moved quickly to make the radical move to steel permanent, literally scrapping its BFR prototype tent and abandoning its lease of a separate facility that was meant to host a more permanent composite Mars rocket factory in the near future. Now, almost exactly a year canceling its Port of LA factory, SpaceX has returned with plans to build and finish new port-based Starship production facilities just a few months from now.

Completed in September 2018, the closest SpaceX ever got to producing its 2017 BFR iteration was a large ring-like composite structure, also known as a barrel section. Measuring some 9m (30 ft) wide and 4-6m (12-20 ft) long, both 2016, 2017, and 2018 variants of SpaceX’s next-generation fully-reusable rocket would have been assembled from a number of similar components — all to be built out of carbon composites with giant mandrels (a bit like inverse molds).

Building giant rockets and the factories needed for production is no less expensive. (Pauline Acalin)
SpaceX’s BFR tent (right) had a flap open on September 18th, 2018, revealing the rocket’s first and only full-scale composite prototype. (SpaceX/Pauline Acalin)
SpaceX’s Port of LA-based BFR development tent ceased to exist after the company decided to scrap it and the entirety of its contents in March 2019. (Pauline Acalin/SpaceX)

While it’s more than likely that SpaceX could have managed the feat, building a reusable orbital spacecraft like Starship out of carbon fiber posed a vast array of challenges. When Musk revealed that SpaceX would move from carbon fiber to steel in December 2018, the CEO went into some detail to explain several of those challenges and why the major change was thus worth the substantial body of work it would force the company to scrap and redo from scratch.

The two biggest hurdles for BFR were quite simple. From a technical perspective, carbon fiber is dramatically less temperature-resistant than most metals (especially steel), meaning that despite it offering a much higher strength-to-weight ratio on paper, almost every inch of the spaceship and booster’s exposed surfaces would have to be insulated. For Starship, this would be exceptionally challenging given that the spacecraft must fundamentally be able to survive numerous orbital-velocity reentries with little to no refurbishment in between. While a steel Starship would still need a proper heat shield on its windward half, the other half of its steel hull could likely be almost entirely unshielded thanks to the fact that most steels remain structural sound at much higher temperatures.

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With a steel hull, Starship’s leeward (non-wind-facing) half can effectively be nude, saving (literal) tons of weight. (SpaceX)

Beyond the “delightfully counterintuitive” technical properties that could make a steel Starship as light or even lighter than the carbon composite alternative, Musk also noted that a huge motivator for the switch was the fact that the cutting-edge composites SpaceX would have to buy were incredibly expensive. In September 2019, Musk stated that composites would have cost some $130,000 per ton, whereas a ton of the stainless steel SpaceX is now using can be purchased for just $2500. In simpler terms, from a material cost perspective, steel Starships and Super Heavy boosters could cost an incredible 50 times less than their carbon composite twins.

Port Factory 2.0

For now, it’s unclear exactly what SpaceX foresees for Starship’s newly re-proposed Port of LA factory. The same primary constraint remains: there is still no affordable way to ship full-scale 9m-diameter Starship hardware by road. The most likely explanation for the resurrected interest in port facilities is that SpaceX still wants to keep some major aspects of Starship manufacturing within reach of California’s vast aerospace talent pool, as well as the company’s own California headquarters, situated just 20 or so miles from Port of LA.

Before SpaceX vacated its prospective BFR factory at Port of LA Berth 240, it had performed a small amount of earthmoving and foundation work. (Pauline Acalin – November 2018)

At the same time, SpaceX probably has all the space it could possibly want at its Hawthorne, CA headquarters after a massive Triumph facility was recently vacated, meaning that any intentional expansion in Port of LA is probably motivated by the need to transport massive rocket parts from California to Texas and Florida. Daily Breeze also reports that “SpaceX would manufacture its…Starship spacecraft and…Super Heavy [booster] on the property” if it receives approval, seemingly implying interest in full-scale rocket production at its prospective port factory.

Regardless of whether SpaceX wants to build smaller Starship subcomponents (i.e. nose cones, header tanks, fins, plumbing, crew compartments, etc.) or complete spaceships and boosters, the company is seemingly far more eager to get port facilities in place, this time around. Specifically, SpaceX told a city council member that it wanted to get a Port of LA facility up and running just 90 days after it expressed new interest in the concept.

At SpaceX’s Boca Chica, Texas outpost, the company has used Sprung Structures to add 100,000+ square feet of enclosed factory space in just a month or two. (NASASpaceflight – bocachicagal)

To do so, SpaceX will copy the methods used to create both Tesla’s General Assembly 4 factory addition and its own massive Starship production space in South Texas, relying on Sprung Instant Structures to erect a massive semi-permanent tent or two in an extremely short period of time. Unfortunately, because of how abruptly SpaceX abandoned its Port of LA factory lease, the company will have to repeat the permitting and environmental review process from scratch, making it very unlikely that it will be able to begin construction within the next month or two.

Regardless, SpaceX certainly remains as agile as ever. Stay tuned for updates on this surprise resurgence of plans for a Port of LA Starship factory.

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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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Elon Musk

Elon Musk is now a remote DOGE worker: White House Chief of Staff

The Tesla and SpaceX CEO Elon Musk is no longer working from the West Wing.

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Credit: Elon Musk/X

In a conversation with the New York Post, White House Chief of Staff Susie Wiles stated that Tesla and SpaceX CEO Elon Musk is no longer working from the West Wing.

As per the Chief of Staff, Musk is still working for DOGE—as a remote worker, at least.

Remote Musk

In her conversation with the publication, Wiles stated that she still talks with Musk. And while the CEO is now working remotely, his contributions still have the same net effect. 

“Instead of meeting with him in person, I’m talking to him on the phone, but it’s the same net effect,” Wiles stated, adding that “it really doesn’t matter much” that the CEO “hasn’t been here physically.” She also noted that Musk’s team will not be leaving.

“He’s not out of it altogether. He’s just not physically present as much as he was. The people that are doing this work are here doing good things and paying attention to the details. He’ll be stepping back a little, but he’s certainly not abandoning it. And his people are definitely not,” Wiles stated.

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Back to Tesla

Musk has been a frequent presence in the White House during the Trump administration’s first 100 days in office. But during the Q1 2025 Tesla earnings call, Musk stated that he would be spending substantially less time with DOGE and substantially more time with Tesla. Musk did emphasize, however, that DOGE’s work is extremely valuable and critical.

“I think I’ll continue to spend a day or two per week on government matters for as long as the President would like me to do so and as long as it is useful. But starting next month, I’ll be allocating probably more of my time to Tesla and now that the major work of establishing the Department of Government Efficiency is done,” Musk stated.

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Elon Musk

Tariff reprieve might be ‘Tesla-friendly,’ but it’s also an encouragement to others

Tesla stands to benefit from the tariff reprieve, but it has some work cut out for it as well.

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tesla employee
(Photo: Tesla)

After Secretary of Commerce Howard Lutnick made adjustments to the automotive tariff program that was initially announced, many quickly pointed to the reprieve as “Tesla-friendly.”

While that may be the case right now, it was also a nudge of encouragement to other companies, Tesla included, to source parts from the U.S. in an effort to strengthen domestic manufacturing. Many companies are close, and it will only take a handful of improvements to save themselves from tariffs on their cars as well.

Yesterday, Sec. Lutnick confirmed that cars manufactured with at least 85 percent of domestic content will face zero tariffs. Additionally, U.S. automakers would receive credit up to 15 percent of the value of vehicles to offset the cost of imported parts.

Big Tesla win? Sec Lutnick says cars with 85% domestic content will face zero tariffs

“This is ‘finish your cars in America and you win’,” Lutnick said.

Many were quick to point out that only three vehicles currently qualify for this zero-tariff threshold: all three are Teslas.

However, according to Kelley Blue Book’s most recent study that revealed who makes the most American cars, there are a lot of vehicles that are extremely close to also qualifying for these tariff reductions.

Tesla has three vehicles that are within five percent, while Ford, Honda, Jeep, Chevrolet, GMC, and Volkswagen have many within just ten percent of the threshold.

Tesla completely dominates Kogod School’s 2024 Made in America Auto Index

It is within reach for many.

Right now, it is easy to see why some people might think this is a benefit for Tesla and Tesla only.

But it’s not, because Tesla has its Cybertruck, Model S, and Model X just a few percentage points outside of that 85 percent cutoff. They, too, will feel the effects of the broader strategy that the Trump administration is using to prioritize domestic manufacturing and employment. More building in America means more jobs for Americans.

Credit: Tesla

However, other companies that are very close to the 85 percent cutoff are only a few components away from also saving themselves the hassle of the tariffs.

Ford has the following vehicles within just five percent of the 85 percent threshold:

  • Ford Mustang GT automatic (80%)
  • Ford Mustang GT 5.0 (80%)
  • Ford Mustang GT Coupe Premium (80%)

Honda has several within ten percent:

  • Honda Passport All-Wheel-Drive (76.5%)
  • Honda Passport Trailsport (76.5)

Jeep has two cars:

  • Jeep Wrangler Rubicon (76%)
  • Jeep Wrangler Sahara (76%)

Volkswagen has one with the ID.4 AWD 82-kWh (75.5%). GMC has two at 75.5% with the Canyon AT4 Crew Cab 4WD and the Canyon Denali Crew Cab 4WD.

Chevrolet has several:

  • Chevrolet Colorado 2.7-liter (75.5%)
  • Chevrolet Colorado LT Crew Cab 2WD 2.7-liter (75.5%)
  • Chevrolet Colorado Z71 Crew Cab 4WD 2.7-liter (75.5%)

These companies are close to reaching the 85% threshold, but adjustments need to be made to work toward that number.

Anything from seats to fabric to glass can be swapped out for American-made products, making these cars more domestically sourced and thus qualifying them for the zero-tariff boundary.

Frank DuBois of American University said that manufacturers like to see stability in their relationships with suppliers and major trade partners. He said that Trump’s tariff plan could cause “a period of real instability,” but it will only be temporary.

Now is the time to push American manufacturing forward, solidifying a future with more U.S.-made vehicles and creating more domestic jobs. Tesla will also need to scramble to make adjustments to its vehicles that are below 85%.

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Tesla Cybertruck RWD production in full swing at Giga Texas

Videos of several freshly produced Cybertruck LR RWD units were shared on social media platform X.

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Credit: Joe Tegtmeyer/X

It appears that Tesla is indeed ramping the production of the Cybertruck Long Range Rear Wheel Drive (LR RWD), the most affordable variant of the brutalist all-electric pickup truck.

Videos of several freshly produced Cybertruck LR RWD units were shared on social media platform X.

Giga Texas Footage

As per longtime Tesla watcher Joe Tegtmeyer, Giga, Texas, was a hotbed of activity when he conducted his recent drone flyover. Apart from what seemed to be Cybercab castings being gathered in the complex, a good number of Cybertruck LR RWD units could also be seen in the facility’s staging area. The Cybertruck LR RWD units are quite easy to spot since they are not equipped with the motorized tonneau cover that is standard on the Cybertruck AWD and Cyberbeast.

The presence of the Cybertruck LR RWD units in Giga Texas’ staging area suggests that Tesla is ramping the production of the base all-electric pickup truck. This bodes well for the vehicle, which is still premium priced despite missing a good number of features that are standard in the Cybertruck AWD and Cyberbeast.

Cybertruck Long Range RWD Specs

The Cybertruck LR RWD is priced at $69,990 before incentives, making it $10,000 more affordable than the Cybertruck AWD. For its price, the Cybertruck Long Range RWD offers a range of 350 miles per charge if equipped with its 18” standard Wheels. It can also add up to 147 miles of range in 15 minutes using a Tesla Supercharger.

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Much of the cost-cutting measures taken by Tesla are evident in the cabin of the Cybertruck LR RWD. This could be seen in its textile seats, standard console, seven-speaker audio system with no active noise cancellation, and lack of a 9.4” second-row display. It is also missing the motorized tonneau cover, the 2x 120V and 1x 240V power outlets on the bed, and the 2x 120V power outlets in the cabin. It is also equipped with an adaptive coil spring suspension instead of the adaptive air suspension in the Cybertruck AWD and Cyberbeast.

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