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SpaceX execs bullish on BFR as Mars rocket test facilities expand in Texas [photos]
Aerial observations of SpaceX’s McGregor, Texas testing facilities on April 17 revealed an unusually frenetic level of construction and expansion centered around Raptor – the rocket engine intended to power BFR and SpaceX to Mars – and a new test-stand, the purpose of which is currently unknown.
With a minimum of 1200 seconds of hot-fires under its belt, SpaceX’s Raptor propulsion program is likely rapidly approaching the end of what is best described as the experimental phase of testing. While this has not been communicated by SpaceX, it is a logical conclusion following several recent developments. Namely the true beginning of BFR test article fabrication and an impressively bullish level of commitment and confidence in the fully reusable launch system demonstrated in the last few months alone by CEO Elon Musk and President/COO Gwynne Shotwell. While Musk is infamous both within and beyond his companies for painfully impractical development timelines, he demonstrated some level of growing consciousness of that fallibility at 2018’s SXSW, stating that he was working on recalibrating his expectations. Without taking a breath, he reiterated his anticipation for short hop tests of the first full-scale spaceship prototype in the first half of 2019.
SpaceX’s three-bay Raptor test stand as of April 17. The middle bay is currently home to the subscale Raptor test program. (Aero Photo)
While anyone familiar with Musk’s timeline antics may roll their eyes and laugh, far more shocking was Shotwell’s sudden pivot towards a new sense of optimism for the BFR program. At Satellite Conference 2018, the typically reserved and pragmatic executive confirmed beyond any doubt that she had become aggressively bullish on the Mars rocket, stating that she believed the spaceship would be ready for suborbital testing in 2019, while the booster-spaceship system could potentially reach orbit by 2020. Musk and Shotwell’s suggestion that BFR’s first suborbital testing – akin to an extreme version of SpaceX’s Grasshopper and F9R programs – is expected to begin in 2019 meshes well with a recent explosion of activity at Port of San Pedro in Los Angeles, CA, thanks to a combination of land acquisition, successful bureaucracy-wrangling, and the first hints of construction and BFR production. It’s highly unlikely that SpaceX would have chosen to temporarily move BFR prototyping into a giant tent on abandoned dock space rather than waiting for port and city approvals for their permanent port factory if they were not keen on moving full speed ahead with the fully reusable launch vehicle’s development.
SpaceX has completed over 1,200 seconds of firing across 42 main Raptor engine tests. pic.twitter.com/EhxbPjd8Cj
— SpaceX (@SpaceX) September 29, 2017
SpaceX’s Director of Real-Estate Bruce McHugh was less confident when he spoke before Port of San Pedro’s board of commissioners on April 19, although all in attendance expressed a huge amount of excitement at the increasingly likely prospects of a huge SpaceX rocket factory materializing in their neighborhood. Local contractors, economic development representatives, and many other community members were eager for the approval and permitting process to finish up, after which SpaceX is characteristically likely to begin demolition and construction in earnest at Berth 240, the prospective site for the company’s first dedicated BFR factory.
Early phases of in-house BFR structures prototyping is taking shape behind the flaps of a custom-ordered temporary tent, something like 60m long, 30m wide, and ~15m tall at the highest point – half an acre of eccentric but functional space for Mars rocket R&D, in other words. The primary benefit of these facilities’ dock-side locations is the minimization of the transportation hell that SpaceX would have had to suffer through to transport 9m-diameter rocket hardware through downtown Los Angeles – feats that would cost as much as $2.5 million one way each time components had to be moved from the Hawthorne factory to the Port of LA, where it would be finally shipped to Texas or Florida.
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- SpaceX’s first major BFR and BFS fabrication tooling, likely being stored temporarily in a tent at Port of San Pedro. Note the tent framework at the top. (Elon Musk)
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- Just a casual line of car-sized steel segments hanging around outside the BFR tent. (Pauline Acalin)
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- It’s understood that SpaceX will eventually move this work to Berth 240 once more permanent facilities are constructed. (Pauline Acalin)
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- SpaceX’s BFR tent and mandrel, caught on April 14th. (Pauline Acalin)
Speaking at a private talk given to MIT campus members in October 2017, attendees reported that Shotwell stated that although “[BFR’s] composite tanks [would] be a challenge [for SpaceX],” the company was already working on maturing the technologies required, and also noted that SpaceX was “building a larger [version of] Raptor right now.” Half a year later, outsiders have heard nothing of any additional carbon composite propellant tank testing at the new 9m diameter, but the existence of custom-ordered (i.e. very expensive and specialized) composite fabrication tooling of the same diameter as BFR effectively guarantees that SpaceX has settled upon and is confident in its approach to manufacturing the massive composite tankage and structures. Along with a similar line of thought, expensive tooling with a fixed diameter also indicates – albeit with less certainty – that the vehicle’s Raptor propulsion system is not expected to change significantly as BFR marches closer to suborbital and orbital testing. Raptor, in other words, is probably considerably more mature than SpaceX’s composite tankage expertise, itself fairly advanced given the mandrel and additional fabrication tooling already present at Port of San Pedro.
And yet, Shotwell’s most telling display of confidence occurred just a handful of days ago at the TED2018 conference. In a lengthy and fairly well-orchestrated interview with the session’s host Chris Anderson, Shotwell repeatedly and happily made comments indicating that she has become extremely bullish on BFR and BFS in the last several months. In her opinion, BFR (and point-to-point Earth transport) will be deployed “within a decade, for sure.” Prices would nominally be “between business and economy,” or a few thousand dollars per person. Speaking on the trip from Earth to Mars, she estimated a three-month journey with BFR Block 1, “but [SpaceX is] gonna try to do it faster.” She further confirmed that SpaceX intends to build much larger BFRs, meshing with Elon’s suggestions that 2016’s ITS concept is now perceived internally as a sort of BFR Block 2. Perhaps most importantly, she qualified her timeline estimates as “Gwynne-time” when Anderson jokingly deadpanned about the infamous Elon-time. Overall, Shotwell came across as more bullish than she has ever been before on BFR’s development and future prospects, including both point-to-point transport on Earth and crewed missions to the surface of Mars – both of which she expected to begin “within a decade, for sure.” Smirking, she quipped that she was “sure Elon would want us to go faster.”
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- BFR heads to orbit in an updated overview of the Mars rocket. (SpaceX)
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- Note the 2017/early-2018 variant’s single delta-wing and extendable leg pods (silver). (SpaceX)
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- According to Hans Koenigsmann, this vision may actually be incompatible if NASA and the US government are given too much control. (SpaceX)
Not one to end on a quiet note, the typically pragmatic executive finished by describing how she believed that spreading human presence throughout the Sol System was only “the first step [towards] moving to other solar systems and potentially other galaxies; I think this is the only time I ever out-vision Elon.” Interstellar travel and faster-than-light propulsion aspirations aside, Shotwell’s comments mark a fairly incredible shift in attitude toward SpaceX’s far loftier ambitions. Musk seems to be working to recalibrate his timelines to be less naive at the same time as Shotwell’s confidence is steadily growing – the two executives, in other words, appear to be rapidly converging upon a middle ground of pragmatic optimism (that or Musk-time is contagious!).
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- Raptor’s McGregor, TX engine test bays are seen here in April 2018. A subscale Raptor prototype is visible in the center bay. (Aero Photo/Teslarati)
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- A new rocket test-stand takes shape at SpaceX’s McGregor, TX facilities. As of just a few months ago, this site was effectively barren of activity. (April 17, Aero Photo)
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- SpaceX’s Merlin 1D (Vacuum and Sea Level) tests stands, as well as a bay for upper stage static fires. (April 17, 2018 – Aero Photo)
As shown above, the level of construction activity at SpaceX’s Texas testing facilities is fairly impressive and could perhaps be seen as evidence that both Musk and Shotwell are speaking from a place of something approaching pragmatism. While the purpose of the new stand (center) is not yet clear, several aspects indicate that it is unlikely to be more mundane. First, the massive water tower (one that did not exist just a month or two ago, might I add) dwarfs anything found at individual engine or upper stage test stands at the SpaceX facility. It’s possible that the existence of the flame trench alone necessitates the inclusion of such a large water suppression system for damage prevention, but the presence of the blue steel skeleton of a new flame bucket (operational iterations shown on the right) suggests otherwise. For example, the Merlin stands have no such water suppression system: they do use water suppression to avoid damaging the ground systems or the engines themselves, but that water is stored in a large ground-level tank. A tower, however, indicates that SpaceX wants much higher water pressures and flow rates to be available at the new stand, a requirement for significantly more powerful tests akin to SpaceX’s full-up Falcon 9 (and Heavy) test stand – the water towers at the S1 stand and this new stand appear to be identical in size.
In other words, it’s more probable than not that this new stand is being built to support either booster static fires or much larger tests of BFR hardware (perhaps multiple Raptors at once, akin to SpaceX’s very early tests of Falcon 9’s nine Merlins). It could, of course, be used for many different tasks, but only time will tell. Given the sheer level of physical progress made in the BFR program and the swelling confidence of Musk and Shotwell, I certainly know where I’d hedge my bets.
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United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.
“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.
🚨 United CEO Scott Kirby calls Starlink “the biggest competitive advantage,” but says it’s temporary.
“I think it’s the biggest competitive advantage. And it’s temporary. Like it’s not, everybody eventually is going to have high speed low earth orbit internet connectivity. It’s going to be a must-have. But we are going to have a few years of being the only airline that has it at scale, and that’s our mission.”
“I think we’re going to convince customers that United is the best airline and we’re going to get customers to switch their loyalty, to get our credit card, switch their loyalty to United. Not because of Starlink. They’re going to try us for Starlink and they’re going to stay with all the other technology, and everything else is better, and the technology in particular is so much better than technology other, and it’s accelerating because we’ve got the right tech stack, and because we’re like, our gap is getting wider and wider with our technology every day.”
Next: LAX becomes United’s first 100% Starlink hub in the first half of next year, and the United app will show your Starlink odds for each flight. https://t.co/hToyFWaWj7
— TESLARATI (@Teslarati) October 27, 2026
United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.
The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.
Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.
Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.
Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.
Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.
The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.
High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.
Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.
Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.
A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”
🚨 Super cool quote from the Cybercab breakdown on the decision to avoid traditional paint:
“One of the most expensive parts of the factory is a paint line… a few hundred million dollars, a million man hours to build one… rule number one at Tesla, question the requirements. Why do you need paint?… the alloys we use in the castings… don’t oxidize and reduce strength over time.” -@larsmoravy
Model Y and Cybertruck bodies are fully coated and painted. On Cybercab, only the side pieces get the anti-corrosion dip coat, and there’s no paint shop at all, which helps cut factory floor space per car by about 50%.
— TESLARATI (@Teslarati) October 26, 2026
The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.
Model Y and Model 3 bodies, by contrast, are fully coated and painted.
Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.
Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.
The secret behind Tesla’s Cybercab Gold goes well beyond just the color
Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.
The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.
Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.
Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.
Investor's Corner
Tesla has a Cybercab problem nobody saw coming
Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.
Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”
Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.
The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.
Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.
The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.
Cybercab engineering deep dive — Robotaxi (@robotaxi) October 26, 2026
The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.
Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”
Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says
Tesla Cybercab’s unorthodox paint process explained
