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SpaceX’s South Texas Starship factory prepares for major upgrades

Starbase's Starship tent factory may be on its way out. (NASASpaceflight - bocachicagal)

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In what is probably a sign of things to come for SpaceX’s nascent Florida Starship factory, the company’s original Starbase facility in South Texas may be about to graduate from tents to more permanent buildings.

More than two years ago, in late 2019, SpaceX followed in the footsteps of Tesla and began constructing a surprisingly advanced factory out of a series of tents. Instead of Model 3s, though, SpaceX would be building and assembling sections of the largest and most powerful rocket ever built. Measuring approximately 120 meters (~390 ft) tall, 9 meters (~30 ft) wide, ~5000 tons (~11M lb) fully fueled, and capable of producing around 7500 tons (~16.5M lbf) of thrust at liftoff, Starship is a fully reusable rocket that aims to perfect what SpaceX has already achieved with partially reusable Falcon 9s and Heavies.

Nonetheless, Starship manufacturing represents a substantial departure from the methods SpaceX uses to build Falcon rockets.

The start of SpaceX’s tented Starship factory, December 2019. (NASASpaceflight – bocachicagal)

Instead of heavily leaning on horizontal integration (meaning that the rockets are primarily assembled in a horizontal orientation), Starship and its Super Heavy booster are almost exclusively assembled vertically. Excluding the machining of major loadbearing structures, Starship manufacturing generally begins with giant rolls of thin (3-4mm or ~0.15 in) stainless steel. SpaceX uses a custom tool to unspool the sheet metal, cuts off a roughly 28-meter (~92 ft) long strip, and then welds the ends of that strip together to produce a cylindrical barrel. Repeat that process 57 times and you end up with enough rings to assemble a full Super Heavy booster and most of a Starship.

However, using increasingly custom tools, SpaceX first stacks and welds those individual rings together to form sections of two, three, four, or five. Each section is then prepared for its specific role with a range of cutouts, plumbing, reinforcements (vertical stringers or circumferential stiffeners), thrust structures (the plates that Raptor engines attach to), and other add-ons. Most importantly, certain stacks of rings are mated with large steel domes – welded together out of prefabricated steel plates – to form forward, common, and aft dome sections. For Starship, SpaceX also assembles the ship’s conical nose section in a similar manner.

A field of various Starship and Super Heavy rings, December 6th, 2021. (NASASpaceflight – bocachicagal)
Dome assembly, April 2020. (NASASpaceflight – bocachicagal)
Nose assembly and outfitting. (NASASpaceflight – bocachicagal)

Virtually all ring, dome, and nose assembly work is conducted in one of three massive tents – each about 114m x 35m (375′ x 110′) – that form the backbone of Starbase’s Starship factory. Finally, SpaceX has built a series of massive open-air bays where, once fully outfitted, each ship and booster section is stacked in a specific order and welded together to complete the basic structures of Starship and Super Heavy.

While SpaceX continues to speed towards the completion of Starbase’s largest and tallest Starship assembly bay yet, the latest news centers around Starbase’s tents. After physically relocating a smaller but still substantial tent believed to be used basic metalwork (laser/water cutting, presses, etc.), SpaceX has rapidly broken ground and partially completed the foundation of a massive, new building believed to be the start of an upgraded Starship factory.

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According to RGV Aerial Photography, SpaceX isn’t merely expanding the main three-tent factory with a fourth larger, permanent building. Instead, it reportedly aims to replace all of Starbase’s tents with a single 300,000-square-foot (~28,000 square meter) building that will be about 18 meters (60 ft) tall and likely measure around 800 feet (250m) long and 400 feet (120m) wide. Starbase’s tents are roughly the same height but their tented roofs mean that only a fraction of that height can be used for ring work and only a fraction of the floor space for taller nose work.

In comparison, a 300,000 square-foot building would have almost two and half times as much covered floor space as Starbase’s three tents – all of which can theoretically be used for ring and nose section assembly. In fact, with a mostly flat 18-meter roof, SpaceX could feasibly expand most ‘stacks’ by a ring or two, which would reduce the number of sections (and thus stacking operations) needed to assemble a ship or booster.

All told, while tents (“sprung structures”) can clearly be indefinite solutions for things like automotive manufacturing, Starship production is one case in which a more permanent flat-ceiling building is undeniably superior. With more than two years of experience and data to draw from, SpaceX may finally be confident enough in its present-day Starship production methods to commit to the construction of Starbase’s next evolution. Stay tuned to see where it leads.

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’s latest Robotaxi job posting takes the whole program a step forward

On Tuesday, Tesla posted a new job for a Senior Insurance Claims Specialist, Robotaxi, the first of its kind.

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(Credit: Tesla North America/X)

Tesla’s latest Robotaxi job posting goes beyond what has been posted in the past and truly takes the entire program a step forward.

Tesla has been hiring some employees for Robotaxi, but a vast majority of the job postings have been related to Vehicle Operator positions, meaning the people who are Safety Monitors or Validation Vehicle Drivers.

Some job postings have hinted at Robotaxi expanding to new cities.

However, on Tuesday, Tesla posted a new job for a Senior Insurance Claims Specialist, Robotaxi, the first of its kind.

The job description says the employee will “oversee the company’s corporate insurance, risk management and surety programs across all business components.” Additionally, it says the position plays “a critical role in managing incident reporting a claim processes for Tesla Robotaxi and ride-hailing operations.”

Essentially, Tesla could be looking to prepare for when it eventually will have to take liability for accidents completely. This would be when the company launches fully autonomous vehicles, meaning Cybercab and the Robotaxi program, specifically. It would also include passenger vehicles with Full Self-Driving.

Tesla is currently operating a Robotaxi program in Austin, Texas, as well as a ride-hailing platform in the California Bay Area.

These programs are the company’s first foray into ride-hailing, with or without someone in the driver’s seat of the vehicle. In Austin, Tesla operates most of its rides without a Safety Monitor in the driver’s seat. Only freeway routes require the Monitor to be directly behind the wheel.

In California, someone sits in the driver’s seat at all times.

The job posting seems to indicate that things could be relatively close in terms of solving self-driving, especially if Tesla is looking to fill a role that would handle autonomous insurance claims.

Of course, it will take Tesla to solve autonomy, and with the company aiming to start Cybercab production (without a steering wheel) in Q2 2025, it surely feels like it is on the brink of something great.

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Tesla snags Lamborghini alum to help in newly entered market

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Credit: Tesla

Tesla has snagged a Lamborghini alum to help with its entrance into a new market, which has proven to be an intricate situation for the automaker.

A report from Bloomberg states that Tesla has hired Sharad Agarwal, who was formerly employed by the Italian luxury carmaker, to run its operations in India. With Lamborghini, he was employed to handle operations in India.

Tesla launches in India with Model Y, showing pricing will be biggest challenge

Tesla has gone through quite a few different team members with its launch in India, starting with a few hirings a few years ago, well before the company actually committed to selling cars in the country.

The move helps Tesla streamline its executive decision-making process, as it previously had employees in India reach out to managers based in China, among other areas. Agarwal will be stationed in India and will handle the company’s operations.

Tesla’s mentality behind the strategy is to have local leadership, something that seems to cater to the market specifically.

Tesla had previously put Isabel Fan, the manager of Southeast Asia for the company, in the position. However, Tesla seemed to want someone who was more permanent and would be dedicated to India exclusively.

India has the largest population on Earth and has a massive automotive market for that reason. Tesla stands to gain a lot from a strong performance in India, and its clean energy vehicles could help with pollution of all kinds in the region.

Tesla’s path to entrance in the Indian market was a long one, as the company tried for nearly ten years to get into the elusive region. Back in 2016, CEO Elon Musk said Tesla “would love to be in India,” teasing the Model 3.

By 2017, Tesla had met with officials from the country, but tried to get import duties down to nothing from 100 percent.

Indian authorities denied Tesla’s request.

For years, Musk met with Prime Minister Narendra Modi to try and iron out a deal of some sort. Nothing truly came to fruition, at least until last year, when real movement started.

By 2024, India had introduced a strategy to reduce import duties for some companies, which was enough for Tesla to make a move. It is now 2025, and the company still has not committed to building a factory in the region. However, it is not completely out of the question.

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Tesla Sentry Mode helps lock up drive-by shooting suspect in Seattle

“A nearby Tesla actually captured the video that showed a man crouched behind a vehicle firing gunshots. A lot of vehicles record, and officers know that Teslas, especially, record, so we use that video all the time in these instances.”

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tesla side repeater camera
(Credit: Tesla)

Police in Seattle, Washington, are crediting Tesla’s well-known Sentry Mode for helping find a suspect in a drive-by shooting case.

A 21-year-old was arrested for an alleged drive-by shooting in the Pioneer Square neighborhood of Seattle this past Sunday, and the leads on the case seemed to be slim.

However, a Tesla parked nearby was able to record the shooting, as well as the car that the suspect hopped in after the crime occurred. It helped police identify the person they were looking for.

Seattle Police Department Detective Brian Pritchard said to MyNorthwest that the Tesla was a critical part of finding the suspect and placing him under arrest:

“A nearby Tesla actually captured the video that showed a man crouched behind a vehicle firing gunshots. A lot of vehicles record, and officers know that Teslas, especially, record, so we use that video all the time in these instances.”

The Tesla footage helped the Police put the suspect into handcuffs about an hour after the crime was committed. They are currently charged with drive-by shooting and unlawful possession of a firearm.

Tesla Sentry Mode is a security feature the vehicle utilizes to help solve crimes like vandalism, but it is also a cool feature that has caught things like accidents and other incidents on camera.

Many people still do not know about it, including the many vandals who keyed or broke the windows of Teslas earlier this year, as people damaged others’ cars in an act of retaliation against CEO Elon Musk when he became involved in politics.

This is far from the first time Sentry Mode has helped Police Departments solve crimes. Last September, we reported on Oakland’s Police Department in California using Teslas near crime scenes to help solve cases.

Tesla Sentry Mode is Oakland PD’s secret weapon against rising crime

Sergeant Ben Therriault, president of the Richmond Police Officers Association, said, “We have all these mobile video devices floating around,” in reference to the Teslas that sit and capture nearly everything that surrounds them.

Sentry Mode has helped officers arrest a variety of suspects, including several people who were allegedly involved in the murder of a 27-year-old woman in Northern California.

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