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SpaceX is building Starship’s first orbital-class booster at a breakneck pace

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Within the last week, SpaceX’s South Texas Starship factory appears to have kicked things into high gear and are now assembling the first orbital-class Super Heavy booster prototype at a breakneck pace.

While the assembly of the Super Heavy known as Booster 4 (B4) wasn’t too dissimilar to what CEO Elon Musk described as a “very hard” build of Booster 3 up to last week, work on the rocket has visibly accelerated. Since January 2020, the process of building Starships and Super Heavy boosters has been fairly simple. Both onsite and offsite, raw materials (mostly sheet steel) are cut, bent, and welded into relatively small parts that then make their way to (or around) Boca Chica by truck, forklift, or crane.

With the help of jigs and good amount of automation, the resulting hardware is then welded together to form domes, header tanks, transfer tubes, tank barrels, flaps, and more. Once subassembly is complete, those integrated rocket sections are reinforced with stringers, ribs, and baffles and outfitted with mechanisms, hardpoints, brackets, plumbing, and more. Finally, final assembly – better known as stacking and by far the most visible step – can begin and technicians stack each of those premade segments on top of each other to form a complete Starship or Super Heavy.

While part fabrication and subassembly integration take weeks or months on their own, those earlier steps can be done concurrently, meaning that SpaceX can prepare sections for several different ships and boosters at the same time. For the last six or so months, at any given moment, SpaceX has had 40-60+ rings in work as part of 15-20+ different ring ‘sections’ visible all across Starbase.

Respectively, each Starship and Super Heavy booster require 20 and 36 rings apiece, while each of the propellant storage tanks SpaceX itself is building for the rocket’s first orbital launch pad require 12-15. All told, SpaceX usually has a combination of around 3-5 ships, boosters, and GSE tanks in some stage of assembly. Unsurprisingly, some assembly tasks are harder than others and building the first in a series of prototypes has almost invariably taken far longer than building those that follow.

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Booster 3Booster 4
LOx tank startMay 20thJuly 16th
LOx tank finishJune 18thJuly 30th
CH4 tank startJune 24thJuly 28th
CH4 tank finishJune 27thJuly 29th
Final stackJune 29thAug 1st?

In that sense, it’s not a huge surprise that SpaceX’s Booster 4 assembly has quickly surpassed the pace set with Booster 3 less than a month earlier. SpaceX began stacking Super Heavy B3 around May 20th, starting with the rocket’s aft liquid oxygen (LOx) tank. Five separate stacks are required to turn the LOx tank’s 23 steel rings into a single structure – a process that took SpaceX about a month with Booster 3.

Booster 3 methane (CH4) tank assembly began a few days after the LOx tank’s completion but proceeded far more quickly, wrapping up just a few days later. Two days after that, those two tank sections were then mated and welded together to complete Booster 3’s full ~65m (~210 ft) tall airframe.

Now, just four weeks after Booster 3 was rolled to the launch pad for proof and static fire testing, Super Heavy Booster 4 is well on its way to reaching its full ~65m height almost twice as quickly. With work beginning around July 16th, B4’s oxygen tank is now just missing an (extremely complex) engine section and the booster’s methane tank was stacked to completion – 13 rings tall – in less than two days. That leaves SpaceX’s first potentially flightworthy, orbital-class Super Heavy booster just two stacks away from completion less than two weeks after its assembly began.

If SpaceX can sustain that pace for another few days, Booster 4 assembly will be the fastest of any full-height prototype ever built at Starbase, most of which have been Starship prototypes that are half to about three quarters the size of Super Heavy.

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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 cites competitive harm in attempt to keep certain crash data private

Tesla wants some data to be kept from the public because competitors could use it for their own benefit.

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Credit: Tesla

Tesla is citing competitive harm as it is attempting to keep certain crash data private from the public in relation to a lawsuit against it and the National Highway Traffic Safety Administration (NHTSA) from the Washington Post.

In a federal court filing seen by Reuters, Tesla said it wanted some of the crash information the Post was attempting to obtain to be kept confidential because it could be used by rivals to assess the company’s self-driving tech.

Tesla touts its self-driving suite as one of the most robust on the market, and those who have used it believe it to be one of the best around. However, accidents do happen, and while Tesla still has not reached full autonomy and tells drivers to continue paying attention to be prepared to take over, the company still seems to take a lot of the blame for them.

There are also some things that could be revealed about Tesla’s self-driving strategy if it were to release the data, the company says. The efficacy of each version of its FSD suite could allow competitors to calculate how many crashes occurred on each release.

Attorneys for the Washington Post said that Tesla’s versions of both software and hardware are not kept private from owners themselves, so the information should be made public.

The NHTSA has been investigating accidents involving Tesla’s Full Self-Driving suite since it opened an investigation last October.

The company is used to dealing with attempts to hinder the progress or capabilities of the FSD suite. When used correctly, it can be a widely beneficial suite that helps make driving less stressful, but Tesla has always been more than vocal that it cannot be used as a replacement for human drivers, at least not yet.

Currently, Tesla Full Self-Driving still requires owners to pay attention and be aware of road conditions, as they may have to take over unexpectedly.

Tesla is hoping to launch its Robotaxi platform in Austin next week on Thursday, as it has reportedly landed on June 12 as its launch date.

Tesla lands on date for Robotaxi launch in Austin: report

However, media skepticism regarding the suite’s capabilities has conveniently started to ramp up as the Robotaxi platform launch nears.

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SpaceX marks 500th Falcon launch with Starlink 11-22 Mission  

The Starlink 11-22 mission marks SpaceX’s 500th Falcon flight & 50th Starlink launch of 2025. Will SpaceX IPO Starlink next?

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SpaceX celebrated its 500th Falcon rocket launch with the Starlink 11-22 mission, a midweek flight from Vandenberg Space Force Base in California.

The milestone was achieved with a Falcon 9 liftoff on Wednesday at 4:40 p.m. PDT (7:40 p.m. EDT, 2340 UTC). It also coincided with the 15th anniversary of the first Falcon 9 launch, underscoring the company’s dominance in the commercial space sector. The Starlink 11-22 mission, SpaceX’s 50th Starlink launch of 2025, highlights the company’s focus on expanding its satellite internet constellation.

Earlier this week, Elon Musk revealed SpaceX anticipates $15.5 billion in revenue this year, surpassing NASA’s $1.1 billion budget for 2026.

SpaceX’s reusable Falcon 9 and Falcon Heavy rockets have driven down launch costs, securing a significant share of the global launch market. In 2024, the company set a record with 134 Falcon launches, making it the world’s most active launch operator. SpaceX aims to surpass this with 170 launches by year-end, fueled by growing demand for satellite deployments. The Starlink constellation is a key revenue driver for SpaceX and remains central to these ambitions. Musk has hinted at a future public offering for Starlink without specifying a timeline.

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Beyond Falcon rockets, SpaceX is advancing its 400-foot Starship system, which Musk envisions as critical for Mars missions. The company’s cost-effective launch services and satellite communications have outpaced traditional space agencies, leveraging commercial demand to fund its interplanetary goals. While NASA focuses on deep space exploration, SpaceX’s revenue model thrives on frequent, reliable launches and Starlink’s expanding reach.

“I would like to thank everyone out there who has bought Starlink because you’re helping secure the future of civilization, making life multi-planetary, and helping make humanity a space-exploring civilization,” Musk said during his Road to Making Life Multiplanetary discussion.

The 500th Falcon launch marks a pivotal moment for SpaceX, reflecting its transformative impact on space access. As the company pushes toward record-breaking launch targets and multi-planetary aspirations, Starlink’s growth continues to fuel its vision, positioning SpaceX as a leader in shaping the future of space exploration and connectivity.

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Tesla is missing one type of vehicle in its lineup and fans want it fast

Tesla is missing one vehicle from its lineup and its fans and owners are hoping the company builds it.

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Tesla’s lineup of vehicles has expanded considerably over the last few years. At first, the company offered the Model S luxury sedan, then the Model X luxury SUV, which has the seats but not the space or the affordability that everyone is looking for.

The Model 3 and Model Y are sedan and crossover vehicles that have launched the company into the mass-market category. The Cybertruck brought out the company’s first-ever pickup design, and while it is unorthodox, it is certainly functional.

Tesla Cybertrucks join Jalisco’s police fleet ahead of FIFA World Cup

But there is one thing Tesla is missing in its lineup, and it is a vehicle type that many have waited for and want. The company currently has not announced any plans to produce it, but its fans are loud and persistent, and we’ve even nudged Tesla to consider making it.

It’s a full-size SUV.

This particular segment is dominated by combustion engines currently: Chevrolet Tahoe and GMC Yukon topped sales with 105,756 and 82,304 units sold, respectively. The Ford Expedition is just behind with 62,007 units sold last year. There are a few formidable competitors on the EV side of things, with the Rivian R1S, the GMC Hummer SUV EV, and even the Kia EV9.

However, Tesla has yet to dip its toe into this market, and it seems many of its fans are willing to admit that the company is missing a true “people mover” with enough space to handle a cross-country road trip with a handful of kids.

Why Not the Model X?

The Model X is likely Tesla’s lowest-selling vehicle. It contributes very little to the overall mission of the company, and even CEO Elon Musk once said that it, along with the Model S, is only produced due to “sentimental reasons.”

When it comes to the X, it’s simply not quite what people are looking for in terms of a “full-size SUV.” Instead, it is more of a van/crossover SUV hybrid. It does not have tons of cargo and interior space.

It does have a lot of great tech, a flashy look, and adequate range for that trip with the kids. It’s a great car, and one that Tesla is planning to refine with an upcoming refresh, its second this decade.

However, it falls short of what would qualify as a full-size SUV, especially considering its third row is a little tight, even for younger children.

But it’s not quite what many would consider as what Tesla needs to fill this void in its lineup.

What Could Be Coming?

Many fans say they would like to see a CyberSUV — something built on the Cybertruck platform but in the form of a full-size SUV. This is not totally out of the question, especially considering Tesla has already made it clear the Cybercab would adopt the same sort of aesthetic as the Cybertruck.

However, we can all agree it’s a far cry from what the Cybertruck truly is, and Tesla likely will not build something that’s even close to the pickup. It already admitted it would not adopt the stainless steel exoskeleton for future vehicles in the Q4 2024 Shareholder Deck.

So, if Tesla were to decide to build something that would be in the full-size SUV segment, it wouldn’t look like the Cybertruck.

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