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SpaceX’s second Super Heavy booster enters production in South Texas

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In a rare burst of visible activity, SpaceX’s South Texas Starship factory has begun fabricating a second Super Heavy booster and taken a significant step forward on the first prototype.

Set to be the largest operational rocket stage ever built by more than a factor of two, Super Heavy is the booster tasked with launching a fully fueled and loaded Starship (~1400 mT or 3 million lbs) out of the bulk of Earth’s atmosphere. Powered by up to 28 Raptor engines, Super Heavy and Starship will weigh upwards of 5000 metric tons (~11 million lbs) and produce anywhere from 5600 to 7700 metric tons (12.5-17 million lbf) of thrust at liftoff.

Most importantly, though SpaceX CEO Elon Musk has noted that an optimized Starship might be able to reach orbit on a one-way trip, a giant, reasonably efficient booster like Super Heavy is necessary to send Starship into a healthy orbit with all the extra hardware and mass needed to make the orbital spaceship reusable. More than twice as heavy and two-thirds as tall as SpaceX’s workhorse Falcon 9 rocket, that will be no small feat.

(SpaceX)

Following the appearance of Super Heavy booster number 1’s (BN1) unique common dome, extra-large ‘transfer tube’ segments, and a donut-like eight-Raptor thrust section last month, visible booster work settled down for the next several weeks. In the interim, Musk revealed that SpaceX aims to hop the first Super Heavy booster (BN1) just “a few months” into 2021, followed by the bombshell that the CEO wants to eventually catch Super Heavy boosters to avoid the need for landing legs entirely.

Two weeks after that latest info from Musk and a month after major booster-related factory activity, the first hardware intended for Super Heavy prototype BN2 was spotted on January 19th. Featuring a never-before-seen structural addition in the form of what looks like a hexagonal or octagonal steel ring, the booster’s unique forward dome represents the first real evidence of the modifications needed to install a variety of hardware specific to Super Heavy.

The limited nature and number of current views make it hard to conclude with certainty that the BN2 forward dome’s add-on is hexagonal or octagonal – either could technically be made to work. Barring a surprise design change, Super Heavy – like Falcon 9 and Heavy boosters – will sport four equally spaced grid fins and use them to ensure aerodynamic stability and control authority from hypersonic to supersonic velocities. Based on official SpaceX graphics, Super Heavy’s grid fins will be built out of welded steel, measure some 7 meters (23 ft) tall, and likely weigh 5+ metric tons apiece, thus requiring extremely powerful actuation systems and strong structural support.

Like Falcon 9 boosters, Super Heavy will rely on four giant grid fins – fins that need complex actuator systems and structural support. (Richard Angle)

Meanwhile, beyond Super Heavy BN2’s first visible appearance, the process of assembling the first booster prototype also took a significant step forward. Sometime on January 19th, SpaceX ended a long period of inactivity, stacking the first Super Heavy ring sections since November 2020. More specifically, SpaceX teams appear to have installed either one or two four-ring sections on an existing booster segment already inside the high bay.

If at rest on top of the rest of the stack in Mary’s (BocaChicaGal) latest photo, one of two Super Heavy ‘stacks’ inside the high bay is now 12 rings (three sections) tall, representing almost a third of a complete 70-meter (~230 ft) tall booster. As of the most recent look inside the high bay, there were two separate stacks of Super Heavy rings – one with four and the other with eight. Based on the location of the new 12-ring stack, it’s more likely than not that SpaceX has simply combined the 12 rings last seen inside the high bay rather than adding one or two new ring sections to one of the two separate stacks.

Ultimately, the return of Super Heavy stacking activity after a two-month pause is an encouraging sign that SpaceX has settled on a design for the first few prototype boosters and could, in fact, be ready to start testing BN1 “a few months” from now.

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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The Boring Company’s newest Vegas Station has a permit quietly waiting behind it

Sahara Las Vegas opened a new Vegas Loop station, joining an exclusive two resort transit club.

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Sahara Las Vegas opened a new Vegas Loop station Thursday, giving The Boring Company’s underground transit system its northernmost stop yet on the Strip. The station sits at Sahara’s Paradise Road entrance, on the southeast corner of Las Vegas Boulevard and Sahara Avenue, and connects riders to the Las Vegas Convention Center, other Strip resorts on the network and, eventually, Harry Reid International Airport.

The addition makes Sahara the second resort, after Fontainebleau opened its own station in January, to get a stop built at street level rather than tucked into the property itself. Sahara now joins Westgate as the only two Strip resorts offering both a Vegas Loop station and a stop on the Las Vegas Monorail, giving guests two separate ways to get around without leaving the property.

The Boring Company just doubled its tunneling power in Nashville

The bigger news buried in Thursday’s announcement is what comes next. Boring Company has already secured its first permit to tunnel north of Sahara Avenue, extending the network beyond where it currently ends, even though permits to push the Loop toward downtown Las Vegas still haven’t been granted. Crews are also working on a two mile dual tunnel line running from Westgate to a planned station at 4744 Paradise Road, just north of Tropicana Avenue, that Las Vegas Convention and Visitors Authority CEO Steve Hill has said the company hopes to open in time for November’s Las Vegas Grand Prix.

Ridership has grown alongside the buildout. The Loop moved roughly 82,000 passengers during CONEXPO in early March, a total the company highlighted on its own X account at the time, and the system has now carried more than 4 million passengers through 11 open stations since it began running in 2021. The airport connector tunnels, meant to give the Loop a direct link to Harry Reid, have slipped past their original first quarter target and remain under construction, with Boring Company director Mike Baier saying that a full opening is still a few months out.

For Sahara, the calculation is straightforward. Convention traffic drives a large share of Loop ridership, and a station at the property’s front door gives conventiongoers one more reason to book rooms on the Strip’s north end instead of closer to the convention center itself.

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Elon Musk

Tesla’s mysterious Robovan makes a sneak peek with Optimus in Terafab video

Elon Musk shared a new Terafab video showing Optimus, Robovans, and a stunningly futuristic campus.

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SpaceX Terafab rendering

Elon Musk posted a new video of Terafab on X Thursday morning, and the most eye-catching details in it were not the building itself, but two products still awaiting production: Optimus and the Robovan.

The concept render, credited to SpaceX, shows Optimus robots working the grounds of the roughly 2.5-mile-long facility planned for the Gibbons Creek site in Grimes County, while a Robovan glides along an elevated roadway cutting through the building itself, sharing the frame with a Tesla Semi and a Cybercab.

Robovan is the boxy, driverless people and cargo mover Musk unveiled alongside Cybercab at Tesla’s “We, Robot” event in October 2024. He pitched it as a way to move up to 20 passengers at once, or handle freight instead, at a target cost he claimed could fall under a dollar a mile, with no steering wheel or pedals, the same layout as Cybercab. Nearly two years later, Robovan still has no confirmed production timeline and has not shown up in any factory footage, which makes Thursday’s render one of the only recent looks at the vehicle in any form.

Optimus has moved further along. Tesla began converting Fremont’s old Model S and Model X assembly line into a Gen 3 Optimus production line earlier this year, and Musk visited the site on July 1 to mark the changeover. A second, larger Optimus plant is under construction at Giga Texas, targeting volume production in summer 2027 and eventual capacity of 10 million units a year. Tesla AI lead Ashok Elluswamy said this month the robot has “big shoes to fill” in replacing the S and X line, while Musk has repeatedly called Optimus the company’s biggest product of any kind, with a long-term price he has pegged between $20,000 and $30,000.


“Terafab Texas will be the largest and most valuable building on Earth by far,” Musk wrote alongside the clip. “And it will be stunningly beautiful.”

One quote post summed up the reaction: “Futuristic scene with RoboVan + Cybercab + Tesla Semi + Optimus.”

Beyond the vehicles, the architecture wrapped around them stands out too. The building’s facade is canted at sharp angles, with illuminated horizontal bands running through what appears to be a multi level interior visible from outside. Below the elevated roadway, pedestrians walk along a plaza next to a reflecting pool, and the skyline behind the campus is dotted with angular spires that read more like sculpture than infrastructure, a departure from the strictly utilitarian look of Gigafactory Texas or Starbase.

The timing tracks with what Terafab representative Riley Trennell told Grimes County residents on Wednesday, when he said renderings of the facility would be released “within days.” Musk’s post followed less than 24 hours later, and Texas Governor Greg Abbott’s office sent out its own release Thursday confirming the project. As Teslarati reported this morning, Terafab’s tax abatement agreements with Grimes County are now signed and active, and SpaceX has sent the county its first $10 million payment under that deal. The dollar figure tied to this phase of construction, per Reuters, is $16.8 billion, one of the first hard capital expenditure numbers attached to Terafab since Musk unveiled the joint Tesla-SpaceX-xAI venture in March.Reaction on X ranged from enthusiastic to skeptical. “God Bless Texas! Everything is bigger and better in Texas!” one reply read. Another was more measured: “Terafab in a decade…..”

Whether the finished building matches the render is a separate question from whether Musk wanted people talking about the render itself. Less than a day after posting, the video had already crossed 5.5 million views.

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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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