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SpaceX could upgrade Starlink constellation with tens of thousands of satellites

A general overview of Starlink's bus, launch stack, and solar array. (SpaceX)

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Filings and an official statement confirm that SpaceX could eventually build a Starlink internet constellation with tens of thousands of satellites, several times more than the company’s already ambitious plans.

“As demand escalates for fast, reliable internet around the world, especially for those where connectivity is non-existent, too expensive or unreliable, SpaceX is taking steps to responsibly scale Starlink’s total network capacity and data density to meet the growth in users’ anticipated needs.”  

SpaceX – October 15th, 2019

Uncovered through regulatory filings published on the International Telecommunications Union’s (ITU) eSubmission portal, the FCC filed documents hinting at plans for tens of thousands of new communications satellites. It was eventually confirmed by the ITU and eventually the company itself that SpaceX was behind the new filings, altogether accounting for up to 30,000 additional Starlink satellites.

SpaceX’s first 60 Starlink satellites were placed in orbit by a Falcon 9 rocket on May 23rd. (SpaceX)

Prior to this new filing, the ceiling for SpaceX’s Starlink satellite internet constellation was set around 11,900 spacecraft – 4400 in several low Earth orbits (LEO) and another 7500 in very low orbit (VLEO). Put simply, even the most ardent supporters and potential benefactors of such a colossal satellite constellation have never taken those particular numbers all that seriously – 12,000 satellites is nearly six times as many operational spacecraft currently in orbit.

To build even a fraction as many satellites would take resources on the order of a small country without a revolution in satellite manufacturing and mass production. Assuming a cost as low as $5 million per satellite (more or less unprecedented), launching just the first 4400-satellite segment would cost SpaceX a minimum of $22 billion, while the full 11,900 would be more like $60 billion.

B1049.3 lifts off with the first 60 v0.9 Starlink satellites. (SpaceX)

And yet, as improbable as it sounds next to today’s satellite production status quo, CEO Elon Musk indicated that SpaceX’s very first 60 Starlink prototypes – launch in May 2019 – cost less than the launch itself. This implies that the cost of each of those beta spacecraft was probably $1 million at most and likely closer to $500,000 apiece. Around that price point, launching thousands of relatively high-performance satellites becomes far more reasonable, even if the figures are still substantial.

4400 satellites would become ~$2 billion, while ~12,000 satellites would become $6 billion. Combined with SpaceX’s new ITU filings, the current maximum of ~42,000 satellites might cost something like $20 billion – a huge price tag, no doubt, but far from impossible. Important to note is that SpaceX almost certainly plans to begin drawing significant income from its Starlink constellation after as few as several hundred satellites have been launched. SpaceX has already raised more than $1 billion to get Starlink close to that point.

A partial overview of SpaceX’s unorthodox Starlink satellite bus. (SpaceX)

Also critical is the fact that building hundreds (let alone thousands) of satellites annually will allow SpaceX to tap into economies of scale quite literally unprecedented in the history of satellite manufacturing, meaning that it’s hard to accurately judge how low the per-satellite cost might eventually fall. Regardless, at the moment, SpaceX’s filings for an additional 30,000 possible satellites are undoubtedly more of an act of “just in case” than a sign of firm plans.

In the present, SpaceX has plans for as many as four additional Starlink v1.0 launches between now and the end of 2019, although it looks likely that that may shrink to 1-2 missions. The next Starlink mission (deemed Starlink 1) is expected no earlier than late-October or November.

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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 CEO Elon Musk denies ridiculous Gigafactory Shanghai rumor

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(Credit: Tesla)

Tesla CEO Elon Musk took to his social media platform X on Thursday night to deny a ridiculous rumor regarding the sale of the company’s Chinese vehicle production plant, Gigafactory Shanghai.

On Thursday, the Wall Street Journal, citing sources familiar with the matter, claimed in a scathing new report that Tesla was exploring a potential sale of the entire China business in an effort to help bolster a potential merger between SpaceX and Tesla.

Musk immediately denied the rumor not once but twice, initially calling it “fake news,” and then calling it “absurdly fake news” in a separate post just a few moments later:

The original poster of the Wall Street Journal article that Musk saw deleted the initial post sharing the headline and the rumored sale of Tesla’s China business.

The report seemed absolutely and unequivocally false to begin with; Tesla’s business in China is among the most important pieces of the company’s business. Not only does the factory supply vehicles for the domestic market, but also for various other markets in Asia and Europe.

China is also one of the largest automotive markets in the world, and Tesla has performed well there despite the robust competition.

The speculation regarding a Tesla and SpaceX merger has started to gain steam this year as the space exploration company went public just a month ago. There has been speculation that Musk will bridge all of his companies under one “umbrella company,” and analysts believe this could happen before the end of the decade.

The Tesla and SpaceX merger everyone is talking about is quietly building

This is the latest iteration of Musk’s very evident war on mainstream media. Reports regarding any of Musk’s companies are quick to get the dreaded “false” or “fake news” response from the CEO when they are unfounded.

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Tesla AI boss reveals how big Optimus is going to get

Tesla’s Optimus chief corrected himself on X, confirming a staggering 10 million robot production target.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla’s Optimus program has a new number attached to it, after Ashok Elluswamy, the executive who has run the humanoid robot program since June 2025, posted a three word correction on X Thursday, “Correction, 10 million robots.”

The line clarifies the long term annual capacity Tesla is building toward its planned second Optimus production line at Gigafactory Texas, a figure Musk has cited repeatedly since last year’s shareholder meeting.

The scale is worth noting, because ten million robots a year would mean Tesla building more units annually than most countries sell in new cars. Tesla has framed this as a second line, not the first. The buildout is happening in two phases: a roughly one million unit per year line inside Tesla’s Fremont factory, installed on the floor space vacated when Model S and Model X production ended earlier this year, and a much larger dedicated facility under construction at Giga Texas that broke ground on its first steel structure in May. That Texas facility is the one Elluswamy’s correction refers to, and is expected to reach volume production sometime in 2027.

Tesla Optimus project fires up as Musk sees production line progress

Elluswamy took over Optimus from Milan Kovac last summer and has spent the months since talking up the program’s trajectory. Elon Musk has also floated the ten million figure at Tesla’s 2025 shareholder meeting.

Ending Model S and Model X production to make room for the first Optimus line was one of the more consequential manufacturing decisions in the company’s recent history, retiring two flagship vehicles in favor of a robot that has yet to enter mass production. Musk has previously estimated per unit production costs at $20,000 to $25,000 once Tesla reaches a million units a year, though he hasn’t said what that cost looks like at ten times the volume.

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Autonomous vehicle red tape gets slashed by Trump Administration

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Credit: Zoox

The Trump Administration today made several key moves to help with the deployment of autonomous vehicles by cutting overreaching red tape that has stifled growth and innovation for years.

The moves, which were put forth by the National Highway Traffic Safety Administration (NHTSA), aim to grant temporary exemptions to at least one company currently, although that could expand in the coming months. Additionally, it will work with organizations to develop standards and a sound but efficient regulatory landscape.

Zoox is the only company mentioned explicitly by the Trump Administration in its press release announcing the new terms today. They will receive a temporary two-year exemption that will allow the commercial deployment of up to 2,500 vehicles annually for two years.

There is a potential exemption for Robomart, Inc., which “requests a temporary exemption from certain FMVSS No. 500 requirements for a low-speed vehicle operated by an ADS without a human driver onboard. NHTSA will publish a separate notice seeking public comment on its merits once the initial evaluation is complete,” the agency said.

Here are the five new terms that Secretary Sean Duffy has implemented through the NHTSA today:

  1. Allow Zoox to commercially deploy its robotaxis through a temporary exemption.
    This temporary exemption will allow the commercial deployment of up to 2,500 vehicles annually for two years, subject to an enhanced, adaptable oversight structure that can evolve as Zoox’s technology advances.
  2. Accelerate development of first-ever AV performance standards through a partnership with SAE Industry Technologies Consortia (ITC).
    This partnership will fund a three-year, $5 million “A2SCEND” consortium, bringing together experts to gather data and accelerate creation of the first-ever AV performance standards. This project will inform a single national standard for AV safety to eliminate the patchwork regulatory landscape that has stifled innovation for years.
  3. Publish an interim final rule that allows vehicles manufactured prior to an exemption to be eligible for a commercial deployment exemption.
    This rule will modernize the application process and improve access to exemptions for innovators, including AV developers, by granting the NHTSA Administrator the discretion to apply temporary exemptions to vehicles manufactured prior to the effective date of an exemption grant.
  4. Streamline the application process for Part 555 exemptions by updating guidance and soliciting feedback from the public.
    By updating the Part 555 exemption process—which allows automakers to temporarily sell a limited number of non-compliant vehicles, primarily to test new technologies—NHTSA is aiming to create a more flexible oversight structure for exemptions and summarize recent AV framework activities, including expanded exemption pathways, streamlined crash reporting, and ongoing efforts to modernize Federal Motor Vehicle Safety Standards (FMVSS).
  5. Establish a new Federal Docket for public feedback on NHTSA’s updated safe AV development and deployment guidance.
    NHTSA is updating its technical guidance for AVs for the first time since 2017—focusing on key safety areas like emergency responder interactions, safety management systems, remote assistance, and post-crash behavior to help the industry scale up driverless deployments safely.

Additionally, the NHTSA said it has modernized some safety standards by proposing updates to:

  • FMVSS 102 – Transmission shifting
  • FMVSS 103/104 – Windshield defrosting and wiping
  • FMVSS 110 – Tire placards
  • FMVSS 135 – Braking systems
  • FMVSS 101 – Controls and displays
  • FMVSS 108 – Vehicle lighting
  • FMVSS 111 – Mirrors and rearview display
  • FMVSS 126 – Electronic stability control systems
  • FMVSS 201/208 – Sun visors and warning labels

These changes aim to make the regulatory process for autonomous vehicles more streamlined and efficient, which could help the U.S. gain dominance over autonomous vehicle systems moving forward.

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