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SpaceX preparing Super Heavy, Starbase for booster’s next steps

Booster 4 awaits its moment in the spotlight. (NASASpaceflight - bocachicagal)

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Amid a flurry of deliveries and work on several new Starship boosters, SpaceX is preparing the first truly finished Super Heavy for its next steps.

Partially completed by early September, Super Heavy Booster 4 (B4) supported SpaceX’s iconic ‘full stack’ fit test back on August 6th before returning to the build site but has mostly just floated around Starbase’s launch and test facilities in the seven weeks since its second trip to the pad. On September 10th, CEO Elon Musk himself suggested that SpaceX had plans to static fire the booster as early as mid-September – more than six weeks ago. Obviously, nothing even approximating Super Heavy testing transpired. Instead, at least relative to rapid-fire Starbase operations in the two years prior, SpaceX has almost absentmindedly worked on the booster, mostly completing partially-finished wire runs that run its full 69m (~225 ft) length.

In the last few weeks, though, the type of work being done on Super Heavy B4 has changed.

Completed on August 6th, Super Heavy B4’s first ‘test’ was more of a photo-op. (SpaceX)
Booster 4 rolled to Starbase’s orbital launch pad for the second time on September 7th. (Starship Gazer)
B4 was removed from the launch mount a second time on September 26th. (NASASpaceflight – bocachicagal)

On September 26th, to give the Starbase construction crew more room to install giant arms on the orbital pad’s ‘launch tower,’ SpaceX removed Super Heavy B4 from the launch mount for the second time, temporarily relocating it to an unused patch of the pad’s old landing zone. Booster 4 hasn’t been moved since. However, while probably a bit slower than SpaceX would have liked, large-scale work on the Starship launch tower was effectively completed last week with the installation of two giant rocket-catching ‘Mechazilla’ arms.

A great deal of work has also been done on Starbase’s orbital tank farm over the last two months, including the installation of the last few storage tanks, the ‘sleeving’ of those tanks, a great deal of plumbing, and the start of real propellant deliveries. Save for a few days spent testing Starship S20 in late September and mid-October, the pad construction crews that have to evacuate the pad for 6-12 hours for every test have had three full months to work without interruption. Perhaps the most optimistic explanation for the unusually long gap between Booster 4 and Ship 20 rollout and testing is that SpaceX consciously chose to put off vehicle tests to avoid disrupting orbital launch site construction and retasked nearly all Starbase workers for that construction.

Regardless, with the launch tower and orbital tank farm now more or less structurally complete and work already underway to prepare the tank farm to support its first booster tests, most of the work that may have been drawing focus and resources away from ship and booster preparations appears to be wrapping up. That may be why, for the third time, SpaceX technicians began removing a number of Raptor engines from Super Heavy B4 around the start of October.

Aside from removing around a third to half of Super Heavy’s 29 Raptors, SpaceX also began slowly but surely installing parts of a steel heatshield designed to protect those engines during ground testing, ascent, and reentry. Newer Raptors have also been trickling from Starbase’s build site to the launch pad for installation on the booster and more engines will likely be (re)installed as heatshield installation progresses.

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The start of Super Heavy’s Raptor shield. (NASASpaceflight – bocachicagal)

Perhaps the most unusual part of recent Super Heavy B4 work is the apparent application of some kind of foam around several racks of pressure vessels (COPVs), hydraulic manifolds, and umbilical connections installed around the booster’s base. Those racks will eventually be enclosed inside steel ‘aerocovers’ already staged beside Super Heavy. A number of Twitter users believe that the foam being selectively applied is for acoustic deadening – meant to protect sensitive electronics, valves, and computers from the brutal environment Super Heavy itself will produce at liftoff and during ground testing.

Ultimately, with Booster 4 work ramping back up and the zenith of orbital pad construction activity now likely behind SpaceX, preparations for major Super Heavy testing will hopefully resume. SpaceX has yet to perform a full Super Heavy wet dress rehearsal (WDR; fully filling a rocket’s tanks and performing a launch countdown) or fire up more than three Raptors on a booster or ship prototype. With any luck, that will finally change in the final months of 2021.

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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Elon Musk

Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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Trump to hand Elon Musk a top honor that traces back to JFK

Trump will award Elon Musk the National Medal of Science at Thursday’s White House summit.

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elon musk and donald trump in front of a tesla cybertruck at the white house

Elon Musk is set to receive the highest honor the U.S. government gives to scientists and engineers.

President Donald Trump will present Musk with the National Medal of Science on Thursday at the White House’s Science: A New Golden Age Summit, Fox News Digital first reported on Wednesday. Google cofounder Sergey Brin, Nvidia CEO Jensen Huang and AMD CEO Lisa Su will receive the same medal, while Dell Technologies CEO Michael Dell and Microsoft CEO Satya Nadella will receive the National Medal of Technology and Innovation. A White House official later confirmed the list to Reuters.

“The Trump administration is grateful for the contributions of these incredible leaders in science and technology. These recipients are helping ensure America keeps leading the world in innovation,” White House spokesperson Liz Huston told Fox News.

It will be the first time Trump has presented either medal in his two terms. Congress created the National Medal of Science in 1959, and the National Science Foundation, which administers it, says 529 scientists and engineers have received it since. A presidential committee reviews nominees, but the president makes the final call.

Thursday’s group of medalists run or founded companies, and three of them sit at the center of the Super Intelligence hardware race that Musk competes in. Huang’s Nvidia supplies the GB300 chips filling SpaceX’s Colossus 2 cluster, while Su’s AMD is Nvidia’s biggest rival in data center GPUs.

Worth noting that Trump’s uncle, MIT physicist John G. Trump, received the National Medal of Science from President Ronald Reagan for his work on ionizing radiation and its uses in medicine and industry.

The Pentagon taps Elon Musk to design the battlefield of the future

For Musk, the medal is the latest sign of how far his relationship with Trump has come since their 2025 split over the “Big Beautiful Bill” and his exit from DOGE. Last week, he sat at Trump’s left during a White House lunch where AI executives signed a voluntary safety accord, and Defense Secretary Pete Hegseth named him to help lead the Pentagon’s Project Meridian study on the future of warfare. Musk has also adopted the administration’s new vocabulary, saying on Sunday that SpaceXAI will be renamed SpaceXSI after Trump ordered federal agencies to replace “artificial intelligence” with “super intelligence.”

Musk has collected science honors before, including the Stephen Hawking Medal for Science Communication in 2019.

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Tesla FSD changed its mind mid-intersection, and it may have saved a life

Tesla shares dashcam footage of FSD Supervised stopping mid intersection to avoid a T-bone crash.

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Credit: @BLKMDL3/X

Tesla is putting another Full Self-Driving save in front of its 24.8 million followers on X.

On Tuesday morning, Tesla’s main account shared a dashcam clip with the caption “FSD Supervised preventing T-bone crash.” The footage came from an owner posting as TheNewGrid, who described what happened at a stop sign: “I looked at the car coming to the stop sign figured they would stop, my car went, then came to a stop mid intersection as they flew by. Had I been manually driving this would have resulted in a crash.”

The sequence is the notable part. FSD had already started crossing when the other driver ran the stop sign. Instead of pressing on, the car braked hard in the middle of the intersection and let the crossing vehicle pass in front of it. By the owner’s own account, they had made the same assumption the software initially made, that the other car would stop, and would not have corrected in time.

The clip is the latest in a run of safety posts Tesla has amplified over the past several days. On Saturday, the company shared a video from Selling Sunset star Jason Oppenheim, who sold his Bentley for a Model Y and said he was buying Teslas with FSD for 10 of his employees. Ashok Elluswamy, who leads Tesla AI, followed up by writing that Tesla self-driving “reacts to other people cutting into your path with super-human response times.” On Monday, a Cybertruck owner posted footage of FSD moving across three lanes from a red light to clear a path for an ambulance approaching from behind.

This recent clip also lands a few weeks after Tesla began shipping Automatic Collision Evasion with FSD v14.3.9, a feature that can activate FSD on the driver’s behalf when a frontal collision is imminent or the driver appears distracted. Elluswamy said in September that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” are coming with v15, the release Tesla has tied to round the clock Robotaxi operation.

The safety messaging matters beyond social media. Tesla has said FSD Supervised was 4.1 times less likely to crash than manual driving across 100 million kilometers on European roads, and it has been putting those figures in front of regulators. Eight EU countries have now approved FSD Supervised, with Croatia the most recent, but the EU’s bloc-wide vote originally set for October 6 has been pushed to December at the earliest.

FSD Supervised is still a Level 2 system, and the driver remains responsible at all times. Even heavy users find reasons to step in. Teslarati’s Joey Klender, who uses FSD for about 76 percent of his driving, laid out five recurring issues on Tuesday that still prompt him to intervene. Clips like this one show the other column of that ledger: moments where the software caught a mistake a human was about to make.

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