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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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3 years ago

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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.

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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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Radical Tesla aero patent may make new Roadster’s ~1-sec 0-60 mph launch feasible

The patent is for a multi-mode active aero system that uses fans and deployable skirts to generate controllable downforce.

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14 minutes ago

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August 5, 2025

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Credit: @SmokeAwayyy/X

A radical new patent from Tesla has provided a potential hint at a technology that the electric vehicle maker can utilize to meet the new Roadster’s ambitious 0-60 mph targets. If the technology outlined in the patent does come into fruition, it could help the Roadster stay planted on the ground even as it executes extremely rapid and demanding driving maneuvers.

The Roadster’s 0-60 mph time

When the new Roadster was announced way back in late 2017, Elon Musk stated that the upcoming vehicle would have a 0-60 mph time of 1.9 seconds. This was impressive, but the new Roadster has become so late that this metric is no longer industry-leading. Even Tesla’s own Model S Plaid, a large and heavy family sedan, can now hit a 0-60 mph time in 1.99 seconds, all for a price that starts just under $100,000.

Back in February 2024, Elon Musk stated that Tesla “radically increased the design goals for the new Tesla Roadster.” He stated that there will never be another car like the Roadster, if it could even be called a car. Musk also added that Tesla is now looking to achieve a 0-60 mph time in less than one second with the new Roadster, though this would be the “least interesting part” of the vehicle.

Inasmuch as a 0-60 mph time of 1 second or less sounds insane, these figures are achieved by vehicles like top fuel dragsters, which could accelerate well under 1 second. Of course, these vehicles are specialized machines and not road legal by any means, so the Roadster would still be in a class of its own if Tesla does manage to achieve a sub-1-second 0-60 mph time.

Tesla’s new aero patent 

A new patent from Tesla has now outlined a technology that could be a perfect fit for the upcoming all-electric supercar. Tesla’s patent is for a multi-mode active aero system that uses fans and deployable skirts to generate controllable downforce. This should pave the way for optimal vehicle grip and performance across varying conditions, from the track to the drag strip.

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Tesla describes the patent’s technology as follows: 

“The system operates by creating bounded (e.g., sealed or partially-sealed) regions beneath the vehicle through the selective deployment of skirts that interact with the ground surface. Fans positioned in airflow pathways that extend to these bounded regions generate low pressure within these areas by extracting air, creating downforce that enhances vehicle grip and stability (e.g., by creating a vacuum, or partial vacuum in the bounded regions).”

If Tesla could indeed create a fully bounded region under the new Roadster using the technology outlined in the patent, the company could all ensure that the all-electric supercar always has perfect traction when it launches. It could also help the vehicle handle better in corners, which would be useful if the Roadster were to attempt setting records in tracks such as the Nurburgring.

Check out Tesla’s patent below.

Tesla Roadster Patent by Simon Alvarez on Scribd

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Tesla’s new Robotaxi geofence shape is an FU by Elon Musk to the competition

Maybe it’s all pareidolia. But maybe it’s not. After all, Tesla embraced the first geofence expansion for what it appeared to be.

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16 hours ago

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August 4, 2025

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tesla austin robotaxi geofence and elon musk laugh from meme review

Tesla expanded its Robotaxi geofence in Austin once again early Sunday morning. The new shape seems to be somewhat of a proverbial, and potentially literal, middle finger to the competition.

If you thought the first expansion was a message to the competition and doubters of the company’s ride-hailing service, you probably will believe the second expansion is an even stronger gesture.

Tesla’s first expansion did not go unnoticed, as its shape was particularly recognizable. The company has always operated with a sense of humor, and it embraced what it did. Some, including me, took it as a message to competitors: We can expand in any direction, in any size, at any time. We’ll prove it.”

They picked a shape and went with it:

Tesla’s Robotaxi expansion wasn’t a joke, it was a warning to competitors

It is evident that Tesla is keeping its humor up to continue to show a few things. The first is that it really can expand in any direction it wants and that’s how it is choosing to show it.

The second, well, maybe it’s an edgier way to show doubters that it is really executing on Robotaxi:

Maybe it’s all pareidolia. But maybe it’s not. After all, Tesla embraced the first geofence expansion for what it appeared to be. This might be a similar occurrence, and it might be sending another message to the competition, critics, and doubters.

The expansion was a near-doubling of the geofence Tesla offered previously. After the initial geofence covered just about 20 square miles, Tesla was able to more than double it to 42 square miles with the first growth. This new geofence shape was just under double, and is about 80 square miles.

Tesla’s rapid expansion has impressed many, especially considering the service area has roughly doubled for the second time in well under two months. The Robotaxi service was first offered on June 22.

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Tesla executes ‘a must’ with Musk as race to AI supremacy goes on: Wedbush

Dan Ives of Wedbush says Tesla made the right move getting Elon Musk his pay package.

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19 hours ago

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August 4, 2025

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elon musk
Steve Jurvetson, CC BY 2.0 , via Wikimedia Commons

Tesla (NASDAQ: TSLA) executed what Wedbush’s Dan Ives called “a must” this morning as it finalized a new pay package for its CEO Elon Musk.

The move helped give Musk his first meaningful compensation at Tesla since 2017, when the company offered a pay package that was based on performance and proven growth. That package was approved by shareholders on two separate occasions, but was denied to Musk both times by the Delaware Chancery Court.

On Monday, Tesla announced on X that it had created a new package that would give 96 million shares of restricted stock to Musk to compensate him for the “immense value generated for Tesla and all our shareholders.”

The details of the pay package are designed to retain Musk, who has voiced some concerns about his control of Tesla, as “activist shareholders” have used lawsuits to disrupt the previously approved package.

You can read all the details of it here:

Tesla rewards CEO Elon Musk with massive, restricted stock package

Ives says Musk’s retention is ‘a must’

Ives said in a note to investors on Monday that with the raging AI talent war that Tesla made a smart move by doing what it could to retain Musk.

He wrote:

“With the AI talent war now fully underway across Big Tech, we believe this was a strategic move to keep TSLA’s top asset, Musk, would stay focused at the company with his priority being to bolster the company’s growth strategy over the coming years. With this interim award increasing Musk’s voting rights upon this grant, which Musk honed in on and mentioned was increasingly important to incentivize him to stay focused on the matters at hand, this was a strategic move by the Board to solidify Musk as CEO of Tesla over the coming years with this framework for Musk’s pay package and greater voting control removing a major overhang on the story.”

He went on to say:

“While the groundwork is now in place for the next few years, it will be critical for the Tesla Board of Directors to get this long-term compensation strategy in place prior to the company’s November 6th shareholder meeting which would address the elephant in the room and remove a significant overhang on the stock.”

Wedbush maintained its Outperform rating and its $500 price target on the stock.

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