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SpaceX’s second flight-proven Starship makes way for next ‘test tank’
Four days after the rocket’s hop debut, SpaceX has safely returned its second flight-proven Starship prototype to an assembly building for refurbishment, making way for a new ‘test tank’ at the launch pad.
Known as Starship serial number six (SN6), the ~30m (~100 ft) tall prototype became the second full-scale Starship to take flight on September 3rd, following in SN5’s footsteps to reach a similar ~150m (~500 ft) apogee before gently landing. More or less identical to SN5’s own August 4th hop debut, it marked the second hop of an entirely separate Starship prototype in 30 days – a feat almost certainly unprecedented in the history of large-scale rocket development.
Significant work remains to speed up the post-hop process, which appears to currently amount to some ~48 hours of gradual, uncontrolled detanking and depressurization. Regardless, a bit least than four days after a successful launch and landing, Starship SN6 was rolled back to SpaceX’s Boca Chica, Texas production facilities around 9am CDT, September 7th. Just five hours after that, Starship test tank SN7.1 – the second in a planned series of two – was loaded onto the same transporter and shipped down the road to the launch pad.
Since its first hop, over the last 30 days, SpaceX has inspected and refurbished Starship SN5 to help support what CEO Elon Musk has described as “several short hops to smooth out [the] launch process.” SN6’s success (and the intact launch infrastructure it thus left behind) now means that SN5 will almost certainly be reused in the near future. It’s unclear how many hops will be needed for Starship launch operations to be optimized into a smooth process but 4+ (2 x SN5, 2 x SN6) seems to be a safe bet.
However, SN5’s second hop will have to wait. Up next on SpaceX’s South Texas manifest is the fifth in a series of intentionally destructive tank tests, used to qualify (or disqualify) new Starship designs, manufacturing techniques, and materials. Known as Starship SN7.1, this particular test tank is the second in a series of two meant to determine the capabilities of a new steel alloy.
The first tank, SN7, was (successfully) tested to destruction on June 23rd and is believed to have reached record pressures before it failed. Perhaps more importantly, an unintentional leak during one of SN7’s first pressure test attempts proved that the new 304L (-ish) steel alloy it was built out of would make certain failure modes far less catastrophic (i.e. a leak instead of a violent rupture).
SN7 was a single basic test tank: an upper dome, lower dome, and three steel rings. SN7.1 is significantly more complex, adding a skirt section with hold-down clamps at the base and replacing the aft tank dome with a thrust dome and thrust puck (Raptor engine attachment points). SN7 was simply loaded with cryogenic liquid nitrogen and pressurized. SN7.1 – thanks to the addition of a thrust puck and skirt section – will perform similar cryo pressure tests but will also be subject to the simulated thrust of three Raptor engines with a series of hydraulic rams.
As of now, SpaceX has road closures scheduled today and tomorrow (Sept 8th) from 8am to 8pm CDT – tomorrow likely being the earliest opportunity for SN7.1 testing to begin.
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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:Â
“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.Â
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.Â
“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.Â
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.Â
“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.Â
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
