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SpaceX’s upgraded Starship factory begins to take shape in South Texas

(NASASpaceflight - bocachicagal)

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After a few months of foundation work, SpaceX has begun assembling the first section of a vast new Starship manufacturing building that will eventually replace a series of tents also known as ‘sprung structures’.

SpaceX and its contractors began erecting those tents in late 2019 after a mostly successful series of tests involving Starhopper – a steel rocket built on an unprotected concrete lot – and shortly before a less successful attempt at testing the first truly Starship-esque prototype. Inside and around those new tents, SpaceX took steps to significantly upgrade its Starship production methods and assembly facilities, ultimately settling on a process that is still very familiar more than two years later.

Nonetheless, in typical SpaceX fashion, the company appears to have outgrown those tents and set its sights on constructing a brand new Starship manufacturing facility – traditional roof and all – that will likely replace most or all temporary Starbase structures in the near future.

As previously discussed on Teslarati, documents submitted to a Florida water management agency have already revealed plans for a similar East Coast Starship factory and shed light on what the first unofficially named ‘Starfactory’ might look like in Texas.

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“According to RGV Aerial Photography, SpaceX…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.”


Teslarati.com – March 4th, 2022

A month and a half later, SpaceX (or its contractors) began raising the first steel beams of the new building and made significant progress in just a handful of days. The first vertical beam was erected on April 19th. Around 48 hours later, several roof beams measuring a good 200+ feet (60+ meters) wide were assembled out of smaller pieces and installed on top of the structure’s vertical beams. As-is, the structure likely represents a good view of the front profile of the first of three new Starship production buildings that will eventually be joined to form one giant, monolithic rocket factory.

From nothing to a substantial frame in two days. (NASASpaceflight – bocachicagal)

Notably, the skeleton of the building appears to be closer to 40-50 feet tall instead of the 60 feet predicted – short enough that it likely won’t allow SpaceX to increase the height of the different sections of stacked steel rings that make up most of Starship and Super Heavy. It’s possible that another level will be added for utilities and bridge cranes but the framework currently being installed will likely cap the height of Starship sections at five standard rings (9m/30ft tall). It’s not impossible that yet-to-be-constructed sections of the new factory will be taller, but that would run counter to SpaceX’s established method of production, in which Starship sections move through multiple tents throughout assembly and outfitting.

Construction of the new factory began adjacent to Starbase’s existing tents. As work progresses and the framework turns into a real building, it remains to be seen if SpaceX will use the first building to trial a number of production upgrades, fill it with new Starship production equipment under the same paradigm as existing methods, or physically relocate an existing assembly line inside it.

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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 faces Full Self-Driving pushback in EU over ‘speeding’

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Credit: Tesla

A new report from Reuters claims that a transport authority in Sweden is pushing back against the approval of Tesla’s Full Self-Driving suite because it will travel over speed limits.

The report says the Swedish Transport Administration (TRV) recommends the European Union votes against FSD’s approval. TRV believes it should not be approved until Tesla disables FSD’s ability to speed.

TRV sent a letter to the European Union’s Technical Committee on Motor Vehicles (TCMV), which is set to meet on June 30 to discuss the potential approval of the Tesla FSD suite in the country. Tesla, which has received various approvals in Europe over the past two months, has not provided a comment.

Tesla Full Self-Driving gets first-ever European approval

Teslas operating on FSD do travel over the speed limit, depending on the Speed Profile that is chosen. Drivers have the ability to disengage FSD at any point; Tesla specifically states that those supervising the suite are responsible for its actions.

Let’s cut to the chase: humans operating any vehicle speed almost daily in the United States. Realistically, speed limits in the U.S. are more frequently treated as speed minimums. However, other countries are different, and driving behaviors are less aggressive.

TRV believes that “allowing automated systems to systematically exceed legal speed limits…risks undermining both the legal framework and the expected safety benefits of ​vehicle automation,” the report stated. It’s surprising that Tesla has not received this claim from other countries previously.

This could be a good argument to bring Max Speed back, the setting that previously allowed the driver to choose the absolute fastest the car would travel.

This would still put the responsibility of supervision in the hands of the driver. It would allow the driver to choose whether the car would travel over the speed limit or not, acknowledging that they set the speed, and if they get pulled over, there would be no ability to argue it.

However, it does not seem as if this is something Tesla will do, especially considering many U.S. drivers have requested the feature in an effort to eliminate speeding or at least tone it down. The company has not shown any interest in bringing it back.

Tesla has approvals for FSD in Europe in Estonia, Lithuania, Denmark, the Netherlands, and Belgium.

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Tesla teases greater Grok FSD integration and ‘Banish’ feature ‘in about 3 months’

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Credit: Tesla

Tesla is going to let you guide Full Self-Driving with Grok in 3 months, CEO Elon Musk confirmed on X.

The response from Musk, which revealed Tesla plans to allow drivers to effectively control the car and its navigation more explicitly using Grok, puts the feature for about September.

A Tesla owner said that Full Self-Driving is great, but owners should be able to “converse with Grok like we can with an Uber driver.” She then used examples like, “Grok, turn right here,” and “Drop us off right here, we’ll walk due to traffic,” and finally,” Drop at entrance first, then park far away.”

Coincidentally, the final piece of dialogue would also mean features like Banish are potentially on the way soon.

Banish is also referred to as “Reverse Summon,” and would enable the car to self-park while dropping occupants off at their destination.

This would be a great way to improve the overall experience while supervising FSD. Navigation is already a major painpoint that many owners complain about. Manual overrides when a maneuver is requested or canceled (like using the turn signal stalk to override a navigation route), do not always work.

The feature could be especially useful in street parking scenarios in a city, where spots are sometimes tough to come by. Many of us who grab dinner in a more populated area will park a street or two over from wherever we’re going, because sometimes you know that’s the best you will get. If a driver using FSD could say, “Hey Grok, turn right here on Queen St. and park in that open spot on the right,” it could save a lot of confusion FSD might have on its own.

Musk teased that a similar feature was “coming” back in February:

Tesla Full Self-Driving set to get an awesome new feature, Elon Musk says

It is certainly surprising that Tesla is doing it at this point. The company’s more recent moves have been more evident of taking control and inputs away from humans and putting them in the AI’s hands more frequently. The biggest example of this was taking away Max Speed in AI4 cars, giving us Speed Profiles, and not having any input on the fastest speed the car will travel.

Of course, giving navigation preferences to Grok is availble already in Teslas, but not at the drop of a hat. Instead, you can suggest a certain route at the beginning of your drive.

Here’s an example of that from December:

Finally, the original post that Musk responded to mentioned a parking preference after dropping off the occupants, which describes the Banish feature that Tesla has teased for years.

We’re not sure if Musk was responding more to the ability to guide the car with Grok, or whether he also was including Banish in the three-month prediction timeframe.

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Tesla Cybercab has one important piece that AI4 cars might need for FSD

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Credit: @tpgoebel | X

A close-up image of a Cybercab engineering vehicle in Peabody, Massachusetts, reveals a compact triangular side repeater camera housing equipped with an integrated washer mechanism.

This seemingly small hardware addition could prove to be one of the most critical components for achieving reliable, unsupervised Full Self-Driving (FSD) — not just for the dedicated Robotaxi but potentially for existing AI4-equipped vehicles as well.

The washer system’s importance cannot be overstated in Tesla’s vision-only autonomy approach. Cameras are the sole sensory input for the neural networks powering FSD, constantly interpreting the environment for safe navigation. In real-world conditions, however, lenses quickly accumulate rain, snow, mud, dust, or road spray.

Many of us Tesla owners, especially those who deal with any sort of winter weather at all, know the all-too-common alert that pops up when cameras are obstructed:

Even brief obstructions can drop perception confidence, trigger safety disengagements, or force the vehicle to pull over, although these are relatively rare. Instead, most of the time, the camera will need a wipe from the owner next time they stop the car.

But unlike human drivers who can manually clear their view, a Robotaxi operating 24/7 without a steering wheel or mirrors must maintain pristine vision autonomously. The Cybercab’s side repeater washer delivers targeted cleaning bursts precisely where needed for merging, lane changes, and blind-spot monitoring — functions that demand uninterrupted visibility from the external cameras:

This hardware directly tackles a known pain point in current FSD deployments. Owners frequently report camera-related alerts during inclement weather, which is understandable, but needs to be solved for a true autonomous experience.

For a production Robotaxi fleet aiming for high utilization and minimal downtime, robust washer systems represent a foundational reliability upgrade; essentially, they’re a must-have. Early sightings suggest the design may extend to rear cameras as well, creating a comprehensive cleaning architecture that keeps the entire vision suite operational in harsh environments.

Without it, even the most advanced neural nets struggle when their “eyes” are compromised.

What Does This Mean for AI4 Cars?

This Cybercab detail raises timely questions for AI4 cars already on the road. While Hardware 4 delivers superior compute and camera resolution compared to earlier versions, production models typically lack dedicated side and rear washers. Tesla has included them on Model Y robotaxis that it is using in the fleet:

Tesla Robotaxi has a highly-requested hardware feature not available on typical Model Ys

As Tesla refines unsupervised FSD for broader release, the gap in environmental resilience becomes evident. Software improvements can help mitigate issues, but they cannot fully replace physical cleaning in heavy rain or muddy conditions. Analysts and owners increasingly speculate that AI4 vehicles may eventually require similar washer retrofits — or a future AI4.5 variant — to match the Cybercab’s all-weather readiness and support the same level of autonomy.

As testing progresses, the Cybercab’s washer mechanism highlights Tesla’s pragmatic focus on real-world robustness. It may well become the hardware piece that determines how quickly and reliably FSD scales from prototypes to everyday vehicles.

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