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SpaceX ships Starship hardware from Florida to Texas to speed up production

SpaceX has quietly shipped hardware for the next Starship prototype from Florida to Texas. (NASASpaceflight - bocachicagal)

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After appearing unexpectedly at SpaceX’s Port Canaveral docks last month, several large pieces of Starship flight and manufacturing hardware were successfully shipped from Florida to Texas, arriving at the company’s Boca Chica build and launch site two weeks ago.

Previously discussed on Teslarati, the hardware transfer signals a significant shift in the development strategy for SpaceX’s next-generation Starship-Super Heavy launch vehicle. Most notably, SpaceX has chosen to prioritize Texas in the near term while the company’s Florida facilities instead aim for longer-tail milestones like the first Super Heavy-capable launch site and a new production facility located much closer to that launch site.

While the hardware SpaceX has sent over is relatively minor in the scope of producing a brand new Starship prototype, it will at least somewhat expedite the process thanks to the inclusion of what appears to be a completed propellant tank dome. Additionally, it’s possible that this December 8th hardware delivery will not be the last – a large amount of hardware remains at SpaceX’s Cocoa, Florida Starship production facility, including several ring sections and a nearly finished nose section, among a number of other parts.

As discussed last month, SpaceX has reportedly decided to more or less shutter its Cocoa facilities, transferring all permanent employees who wished to stay to Boca Chica, TX, Cape Canaveral, FL, or Hawthorne, CA facilities. SpaceX’s Starship presence in Florida is in no way done but it does sound like it’s in for at least several months of downtime.

“According to former Cocoa employee that spoke to reporter and channel creator Felix Schlang, SpaceX has reportedly transferred up to 80% of the Starship facility’s workforce to other groups in Florida and Texas. Instead of the friendly internal competition that pitted Cocoa against Boca Chica in the race to first Starship flight, SpaceX is temporarily slowing down its Florida build operations and will redirect as much of its workforce and resources as possible to Boca Chica.

Schlang’s source says that this will likely result in several months of relative downtime in Florida, while he was also told that Starship Mk2 and Mk4 are now effectively dead before arrival as a result of several challenging and reoccurring technical issues. Starship Mk2 likely shares some significant heritage with Starship Mk1, which lost its top during a pressure test. Roughly two-dozen steel Starship Mk4 rings may also be scrapped after SpaceX’s Florida team could not overcome a technical hurdle. Per the source, many of those single-weld steel rings were slightly different diameters, making it next to impossible to build a sound pressure vessel (i.e. Starship Mk4) with them.”


Teslarati.com — December 2nd, 2019

In line with that, SpaceX loaded transport ship GO Discovery with two large steel mounts and a finished tank dome originally believed to be intended for Starship Mk4 and Florida Starship production in general. Those parts arrived in Texas around five days later on December 8th and were rapidly moved from Port of Brownsville to SpaceX’s Boca Chica production facilities.

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The ring-like steel structures will likely take the place of (or complement) the concrete structures SpaceX used to mount and assembly Starship Mk1. Likely significantly lighter, steel ring mounts allow far easier access underneath for technicians and engineers while also being much easier to transport in the event that SpaceX wants to reorganize its Starship ‘factory’.

While they may look rather insignificant on GO Discovery, those steel assembly rings are absolutely colossal. (NASASpaceflight – bocachicagal)
Starship Mk1 is pictured here on October 21st. SpaceX already built a similar steel assembly ring in situ, while the rings from Florida will allow for more work to be done in parallel. (NASASpaceflight – bocachicagal)

Since arriving at the Boca Chica build site, SpaceX stored the assembly rings off to the side while the Starship Mk3 tank dome (i.e. bulkhead) was situated more centrally. So much is going on at SpaceX’s Boca Chica facilities that it’s no longer easy to determine what is being worked on just from observing, but it’s clear that the employees are working around the clock to prepare for Starship Mk3 assembly.

SpaceX continues to experiment with different methods of welding and assembly. On the right is a Florida-built Mk3 dome, while new hardware – visibly using more base panels – has just entered the early stages of welding. (NASASpaceflight – bocachicagal)

One or two new tank domes in various states of production are visible, contractors are constructing a warehouse-sized sprung structure (i.e. tent), and technicians are working to refine improved methods of forming the cylindrical steel rings that make up most of Starship. It can’t yet be said that Starship Mk3 has truly begun to take shape, but it’s clear that the goal is to ensure that the process is dramatically faster than it was with Starship Mk1, which took at least half a year to go from first ring stacking to pressure testing.

It’s safe to say that 2020 is going to be an incredibly busy and productive time for SpaceX’s next-generation rocket.

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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 Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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