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Falcon 9 B1047 seen aboard SpaceX drone ship Of Course I Still Love You. (SpaceX) Falcon 9 B1047 seen aboard SpaceX drone ship Of Course I Still Love You. (SpaceX)

SpaceX

SpaceX’s first dedicated Starlink launch announced as mass production begins

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SpaceX has announced a launch target of May 2019 for the first batch of operational Starlink satellites in a sign that the proposed internet satellite constellation has reached a major milestone, effectively transitioning from pure research and development to serious manufacturing.

R&D will continue as SpaceX Starlink engineers work to implement the true final design of the first several hundred or thousand spacecraft, but a significant amount of the team’s work will now be centered on producing as many Starlink satellites as possible, as quickly as possible. With anywhere from 4400 to nearly 12,000 satellites needed to complete the three major proposed phases of Starlink, SpaceX will have to build and launch a minimum of ~2200 satellites in the next five years, averaging 37 high-performance, low-cost spacecraft built and launched every month for the next 60 months.

A shift in the Stars

Despite the major challenges ahead of SpaceX, things seem to be going quite smoothly with the current mix of manufacturing and development. As previously reported on Teslarati, SpaceX CEO Elon Musk forced the Starlink group through a painful reorganization in the summer of 2018, challenging the remaining leaders and their team to launch the first batch of operational Starlink satellites no later than June 2019. As a consequence, a sort of compromise had to be reached where one additional group of quasi-prototype satellites would be launched before settling on a truly final design for serious mass-production.

According to SpaceX filings with the FCC, the first group of operational satellites – potentially anywhere from 75 to 1000 or more – will rely on just one band (“Ku”) for communications instead of the nominal two (“Ku” and “Ka”), a change that SpaceX says will significantly simplify the first spacecraft. By simplifying them, SpaceX believes it can expedite Starlink’s initial deployment without losing a great deal of performance or interfering with constellations from competitors like OneWeb.

OneWeb’s preliminary satellite production facility. (OneWeb)
SpaceX’s own Starlink deployment mechanism may look quite similar to this OneWeb-inspired render from Arianespace. (Arianespace)

Somewhere along the line, SpaceX would iteratively improve each subsequent ‘generation’ of Starlink satellites until they reached the nominal performance characteristics outlined in the company’s original constellation application. Knowing SpaceX, improvements would continue for as long as lessons continued to be learned from operating hundreds and eventually thousands of orbital spacecraft.

As one concrete example, recent SpaceX FCC documents stated that the first 75 Starlink spacecraft would feature a less-optimized reentry design, meaning that a select few components will not entirely burn up during reentry, creating debris that poses a slight added risk in the eyes of regulatory bodies like the FCC. After those first 75 spacecraft are built and launched, SpaceX will introduce upgrades – already planned and designed – that will reduce the surviving reentry debris (and thus their risk to humans below) to zero.

While the FCC has yet to grant SpaceX’s requested modifications, the other major goal is to reduce the operating orbit of the first phase of 1584 satellites to 550 km (340 mi), a change that SpaceX says will drastically reduce the potential lifespan of any orbital debris in the unlikely event of their creation. A lower altitude also places a major cushion between SpaceX’s first ~1500 satellites and the orbits of several other planned constellations, including OneWeb and Telesat.

Hello, Production Hell, my old friend

Meanwhile, SpaceX’s Starlink program has begun the often painful steps of transitioning from a venture primarily focused on research and development to one focused mainly on building production lines and supply chains and manufacturing hardware. SpaceX’s Starlink facilities are currently housed in three nearby buildings located in Redmond, Washington, likely offering approximately 150,000 square feet (14,000 m^2) for a mix of office, development, and production spaces. At least one of the three non-office buildings could potentially become dedicated to production while one building – approximately 40,000 ft^2 (~3500 m^2) – has already been completely transformed into a prototype of a Starlink satellite production line, supporting manufacturing for first several dozen quasi-prototype spacecraft. For reference, OneWeb’s dedicated satellite factory will feature around 100,000 square feet of space dedicated primarily to production, while the constellation’s satellites will be roughly half as large as SpaceX’s proposed Starlink satellites (~400 kg, 880 lb).

Mass-producing spacecraft at the scale needed to build even half of those needed for the first phase of ~4400 Starlink satellites will be a feat unprecedented in the history of the space industry. Barring FCC exemptions (possible but unlikely), SpaceX needs to launch ~2200 Starlink satellites between now and April 2024. To complete the first phase, the final number of satellites rises to ~4400. Adding on a proposed constellation of very low Earth orbit (VLEO) Starlink satellites, that number rises once more to a bit less than 12,000. Meanwhile, the cost of the satellites needs to be kept as low as possible while their performance is maximized. To put it in automotive terms, SpaceX needs to find a way to do the satellite equivalent of going from building Tesla’s original Roadster to the 2020 Roadster in just a handful of iterative generations and a few years.

One of the first two prototype Starlink satellites separates from Falcon 9’s upper stage, February 2018. (SpaceX)

Perhaps SpaceX will be able to garner invaluable insight from the lessons its sister company learned during Model 3’s torturous “production hell”, in which the car company had to grow its production volume by almost a magnitude as quickly as possible. Ironically, it may even be the case that SpaceX has the easier task relative to Tesla.

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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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Elon Musk

Tesla Roadster owners to get “Flying Stunt Mode” and looping track access

Musk says Roadster owners can command the unveiling stunts autonomously, with a Texas looping track.

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Elon Musk says owners of the new Tesla Roadster will be able to ask the car to perform the stunts Tesla showed at its unveiling, with the car doing the driving itself. Musk made the comment Saturday in a reply on X to tech blogger Robert Scoble, and he added a promise of a looping track at Tesla’s Texas headquarters.

Scoble had argued that the person in the Roadster is not really driving it. In his description, the driver operates a computer that tells another computer what to do, with steering, braking and acceleration all handled by wire. Musk answered, “True. You will be able to ask the Roadster to perform any of the tricks shown autonomously, as it will be sentient. Also, we will have a wild looping track (crazier even than Hot Wheels) at our Texas HQ where you can test out your Roadster.”

At the October 15 event outside Waco, the car drove up a curved ramp until it was upside down, flew off on cold gas thrusters, flipped and landed. It also hovered over a Cybercab, Cybertruck, Semi, Model Y and Model 3 while moving. As we noted in our breakdown of the three Roadster configurations, Musk said at the event that the car “literally is just going to puff itself up” to perform the maneuvers whenever an owner wants. Saturday’s reply adds that the car would run them on its own.

Tesla has described some of the hardware that would make that possible. The Roadster uses steer by wire with a yoke, and its cold gas thrusters rely on electric actuators for small adjustments in flight. A fan system under the car creates suction, which Tesla says is strong enough to hold it upside down, a setup we covered in our look at the Roadster’s fan system and thrusters.

Musk did not say when an autonomous stunt feature might arrive, how it would work, or what he means by sentient. He also gave no size, location or opening date for the Texas track. Production is planned for Giga Texas in 2027 or 2028, and Tesla says the car is not approved for public road use. The Rocket version, the one built to fly, is invite only.

The comment follows a week of Musk teasing the event, including his claim that the demo would be a banger, which we covered before the stream. Tesla reports third quarter earnings on October 21, and shareholders can submit and vote on questions through the Say portal until 4 p.m. EDT on October 20, according to our earnings Q&A preview. A question about autonomous Roadster stunts and the Texas track would be a quick way to get specifics from management.

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Investor's Corner

Tesla’s flying Roadster just revealed something bigger than the car

Analysts say the Roadster demo puts a Tesla and SpaceX merger back on the table.

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Tesla’s new Roadster, upside down and trailing cold gas thruster smoke, flips over a lineup of Tesla vehicles at the Roadster unveiling near Waco, Texas on October 15, 2026. (Image: Tesla)
Tesla’s new Roadster, upside down and trailing cold gas thruster smoke, flips over a lineup of Tesla vehicles at the Roadster unveiling near Waco, Texas on October 15, 2026. (Image: Tesla)

The Roadster unveiling near Waco ended Thursday night, and by Friday morning much of the investor reaction had less to do with the car than with who owns the rocket technology inside it.

Wedbush analyst Dan Ives said the event “puts the Tesla/SpaceX relationship on the table in a tangible way,” pointing to the propulsion, pressure vessel and control hardware sitting on a Tesla product. Gene Munster of Deepwater Asset Management called the demo “a ridiculous display of engineering” with “no commercial value” beyond embarrassing traditional automakers, though he said it showed Musk wants the two companies together.

The more specific forecast came a day earlier from Barclays. Analyst Dan Levy told clients a deal could be announced before Tesla’s annual meeting, which must happen by December 6, and that an announcement in late October or early November could make shareholder approval harder. Barclays expects SpaceX to be the buyer in an all stock deal, with Tesla holders receiving SpaceX shares at a premium, based on market values of roughly $2.1 trillion for SpaceX and $1.5 trillion for Tesla. If nothing lands around the meeting, the bank still sees an announcement within 6 to 12 months.

The Roadster demo just added more weight to merger speculations. Tesla’s demo used cold gas thrusters and pressure tanks of the kind SpaceX uses on Falcon 9, and Musk described the car as a collaboration between Tesla and SpaceX engineers, as we mentioned in our breakdown of the three Roadster configurations.


Musk has not publicly addressed a deal since the event, as far as we have seen. His most direct answer remains the one he gave at the All In Summit, when he said that with so much collaboration, “who can imagine what action one might take” without ruling anything out. Ives has held to a 2027 timeline since his March note, and Musk pushed back on the China piece of the speculation when ARK floated a year end announcement in August.

The next test is Tesla’s third quarter earnings call on October 21. However, we recall in July that Musk told analysts, “we can’t talk about combining companies and that kind of thing on an earnings call,” so a clear answer wouldn’t be expected.

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Elon Musk

Elon Musk says Tesla’s Roadster demo could be a bang, quite literally

Musk says tonight’s Roadster demo will be a banger, maybe literally. The clues add up.

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tesla roadster elon musk flying

Elon Musk spent Wednesday and Thursday stacking teases on top of Tesla’s Roadster event, and the wording is getting harder to read as routine hype. Tesla streams the unveil tonight at 7:55 p.m. Central on X. Musk has called it “a candidate for greatest product demo of all time,” then added that “this demo will be a BANGER, probably metaphorically, though some chance literally.”

The “some chance literally” part is the line to watch. The Roadster has been tied to a SpaceX option package since 2018, and as we reported when the date was announced, the system is reportedly codenamed A71 and uses cold gas thrusters fed by a composite overwrapped pressure vessel, the same tank design SpaceX uses on Falcon 9. Musk has said a thruster equipped car could reach 60 mph in about 1.1 seconds. Cold gas thrusters firing at full output are loud, and reports ahead of the event say the car will be unmanned with spectators kept several hundred yards back. A literal bang could simply mean a demonstration that sounds like one, though it is also an admission that something could go wrong on stage.

Then there is “Timing is everything,” which Musk posted a day earlier. Stocktwits noted that 7:55 p.m. is 19:55 on a 24 hour clock, which echoes 1955, the year Marty McFly travels to in Back to the Future. Musk has made that connection before. In 2019 he replied to an animation of a flying DeLorean by saying the new Roadster “will actually do something like this.” Nothing from Tesla confirms the movie reference, but the stream time was chosen by someone, and Tesla has not been shy about this kind of wink.

Also, Tesla said it moved the event because it “can only be held outdoors,” and Musk then wrote that the demo was postponed “due to high winds,” as Teslarati covered at the time. A car running a standing start in front of a crowd shrugs off wind. A car that leaves the ground does not. The venue near SpaceX’s McGregor test site and the FAA airspace closures reported around the original date point the same way, though we also noted the delay could be a plain safety precaution. Musk has also described the new Roadster as “beyond movies, beyond imagination, beyond human, yet still made by humans on Earth.”

The only official figures remain the 2017 ones: 620 miles of range, a top speed above 250 mph, a 1.9 second 0 to 60 time, and prices of $200,000 for the base car and $250,000 for the Founders Series. Production is expected at Giga Texas in 2027 or 2028. Tesla has said the event will cover pricing, specifications and production targets, and its livestream preview has the full rundown. Tesla reports third quarter earnings on October 21, so whatever lands tonight will be fresh going into that call. We will have live coverage as soon as the stream starts.

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