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SpaceX’s Starbase environmental review suffers third delay

Starbase's orbital launch site; March 2022. (SpaceX)

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The Federal Aviation Administration (FAA) has announced that the completion of a crucial ‘environmental assessment’ SpaceX needs to begin orbital-class Starship launch attempts out of South Texas has been delayed for the third time.

Official known as a programmatic environmental assessment or PEA, the FAA says it started the process in late June 2021 with the goal of verifying that SpaceX’s Starbase orbital launch site (OLS) was mostly benign before the end of 2021. Compared to a regular EA, the programmatic nature of SpaceX’s Starbase review would theoretically allow the company to start small and gradually expand and add new facilities and capabilities without having to restart the arduous review process for each change.

Along those lines, SpaceX’s first draft PEA requested permission for no more than five full-stack Starship launches per year compared to the maximum of 12 Falcon 9 launches or nine Falcon 9 and three Falcon Heavy launches out of Boca Chica that SpaceX had already received permission for from the FAA in 2014.

Unfortunately, even at the time that the start of the process was announced, completing a full PEA in half a year was already unbelievably optimistic. No comparable review, of which there are effectively none, has been completed anywhere close to that quickly. In the face of substantial local opposition, like in the case of Georgia’s Camden Spaceport, even an FAA environmental review for a relatively small rocket launch facility can make little progress after years of tooth-and-nail fighting.

However, the best possible comparison has always been SpaceX’s own environmental assessment for an almost identical orbital-class Starship launch site at Florida’s Kennedy Space Center. Despite the fact that no untouched ground would be broken and even with the apparent might of NASA behind it, it took the FAA and SpaceX about a full year to complete a Pad 39A EA for up to 24 Starship launches per year. As such, the idea that the FAA would be able to complete a PEA for Boca Chica Starship launches in six months was always almost unimaginable.

It should come as no surprise, then, that nine months after SpaceX and the FAA began their Starbase PEA, they appear to be only marginally closer to completing the review. Days before the original December 31st, 2021 deadline, the FAA announced a delay to February 28th, 2022. On February 14th, the FAA announced a second delay to March 28th. Most recently, on March 25th, the FAA announced a third delay to April 29th.

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Put simply, the FAA is effectively saying that it is actually further away from completing SpaceX’s South Texas Starship PEA than it was in December 2021. The extraordinarily opaque nature of the process also means that anyone outside of the loop or without internal sources is left to simply guess what is causing those delays or why the FAA keeps pushing the goalposts back just one or two months at a time when it’s unclear that anyone can actually predict when the process will be completed.

Without journalists filing Freedom of Information Act (FOIA) requests, the full extent of public knowledge about what is causing those delays would be the FAA’s scant few statements on the process. The most valuable information provided thus far is that the FAA is “reviewing the Final PEA,” which does seem to imply some degree of progress. Nonetheless, the agency still included a boilerplate statement noting that it’s “completing consultation and coordination with agencies at the local, State, and Federal level,” making it hard to actually say if any progress has been made. In February 2022, the FAA said it was “continuing consultation and coordination with other agencies.”

In December 2021, the FAA stated that it was “continuing consultation and coordination with other agencies at the local, State, and Federal level” while “SpaceX continues to prepare the Final PEA for…FAA review and acceptance.” By using such vague and unspecific language, the FAA makes what little it does say virtually impossible to parse and barely better than nothing. Solely thanks to documents secured through FOIA, we know that the FAA itself may not actually be to blame for most or all of the PEA’s four months of delays.

Instead, the US Department of the Interior (DOI), Fish and Wildlife Services (FWS), and National Park Services (NPS) may be partially responsible through their required coordination with the FAA, which they appear to be taking full advantage of to exert some form of control over the outcome. Bureaucrats are being bureaucratic, in other words.

Outside of email chains and boardrooms, however, it’s no longer clear that completing the PEA and securing an FAA launch license are the limiting factor for the first orbital Starship test flights. SpaceX CEO Elon Musk recently announced that SpaceX is changing the prototypes assigned to the first full-stack launch – likely to Booster 7 and Ship 24. Super Heavy B7 has yet to begin any kind of testing and Starship S24 is still in several pieces, so it’s safe to say that SpaceX’s new pair are months of concerted testing away from launch readiness.

If anything goes wrong during those tests, any significant design issues are discovered, or any damage is caused, it’s entirely possible that what Elon Musk says could take as few as two months will actually take more like four to six. Only time will tell. For now, the FAA likely has a few months before Starship’s South Texas PEA and full-stack launch license truly become the limiting factor for the rocket’s first orbital launch attempt.

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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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