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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 to launch in India in July with vehicles already arriving: report

Tesla is finally making serious moves toward launching in India, with showrooms opening in July, a report claims.

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Credit: Tesla

Tesla is finally bringing its business to India, a new report indicates, as the company is already shipping vehicles from China to the market where it has attempted to launch business for several years.

We first heard of Tesla planning to launch in India about a decade ago when CEO Elon Musk and Indian Prime Minister Narendra Modi met in California at the Fremont Factory in 2015.

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Over the years, the two have hinted that the automaker would eventually land in India, but issues with import duties have delayed Tesla’s attempts.

Now, there seems to be some serious movement in Tesla’s plans, as it has reportedly shipped the first batch of vehicles from China to India, according to Bloomberg. The outlet says these are Model Y Rear-Wheel-Drive configurations.

Tesla is also planning for other parts of the launch, like preparing for Supercharging, aftermarket parts and merchandise purchasing for vehicle owners and fans, and spare parts from various regions, including the United States, China, and the Netherlands.

The company and the Indian government must have come to some sort of agreement that was catalyzed by Musk and Modi’s meeting in February in the U.S.

It is a long time coming, and it now gives Tesla access to an incredibly vast market in India, where a very small percentage of 2024’s total automotive sales were comprised of electric vehicles.

Another interesting tidbit about the launch is that the vehicles will be coming from Gigafactory Shanghai and not Gigafactory Berlin as previously thought. Reports from other publications, like Reuters, indicated the German production facility was building vehicles for India early last year.

India has a very strict policy that favors domestic manufacturing, which is why the import duties were so high for foreign automakers looking to bring their product into the market. These duties were reduced from 110 percent to just 15 percent, as long as companies aim to invest in India and meet certain investment and sales targets.

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SpaceX and Elon Musk share insights on Starship Ship 36’s RUD

Starship Ship 36 experienced a Rapid Unscheduled Disassembly during a static fire attempt.

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Elon Musk and SpaceX provided an explanation for the Rapid Unscheduled Disassembly (RUD) of Starship Ship 36 on Wednesday. As per Musk, preliminary data suggests that a nitrogen composite overwrapped pressure vessel (COPV) in the vehicle’s payload bay failed below its proof pressure.

On Wednesday evening, Ship 36 experienced a RUD during a static fire attempt. Videos of the incident that were shared online showed Starship Ship 36 exploding into a massive fireball at its launchpad in Starbase, Texas. Images taken in the aftermath of the explosion showed significant damage to the plumbing in the area. The site’s pad structure was also destroyed.

Elon Musk shared some information immediately after the incident. In a response to a post from space enthusiast @Erdayastronaut, Musk stated that “Preliminary data suggests that a nitrogen COPV in the payload bay failed below its proof pressure.”

Musk also noted that, “If further investigation confirms that this is what happened, it is the first time ever for this design.”

SpaceX provided more insight into the incident in a post on its official website.

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“After completing a single-engine static fire earlier this week, the vehicle was in the process of loading cryogenic propellant for a six-engine static fire when a sudden energetic event resulted in the complete loss of Starship and damage to the immediate area surrounding the stand.

“The explosion ignited several fires at the test site, which remains clear of personnel and will be assessed once it has been determined to be safe to approach. Individuals should not attempt to approach the area while safing operations continue,” SpaceX wrote in its post.

SpaceX highlighted that despite Starship Ship 36’s RUD, the incident will not result in any hazards to the surrounding communities in the Rio Grande Valley. And in a post on X, SpaceX also confirmed that everyone in the Starship team was safe and accounted for after Ship 36’s explosion.

While Ship 36’s RUD is a speed bump for the Starship program, SpaceX is a company that is known to grow stronger with every adversity. Thus, it would not be surprising if SpaceX implemented numerous improvements to Starship after this incident–improvements that would make the vehicle more reliable and safer than before.

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Tesla has started rolling out initial round of Robotaxi invites

Tesla is putting safety above all in its initial Robotaxi rollout.

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Credit: @BLKMDL3/X

Tesla has started rolling out an initial round of invites for its upcoming Robotaxi service in Austin, Texas.

Screenshots shared by several Tesla community members who received the invites provided a quick overview of the autonomous ride-hailing service.

As noted in a techAU report, the initial round of Robotaxi service invites has gone to longtime Tesla owners and active members of the EV community. These include owners such as @SawyerMerritt, @BLKMDL3, @WholeMarsBlog, @ItsKimJava, and @HerbertOng, all of whom shared screenshots of the invitation that Tesla has sent about the upcoming service.

You’re Invited to Early Access of Tesla Robotaxi!

The Future is Now! You’re invited to Early Access of Tesla’s Robotaxi service in Austin, TX!

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As an Early Access rider, you can be among the first to use our new Robotaxi App and experience an autonomous ride within our geofenced area in Austin. Through this exclusive preview, you’ll have the opportunity to provide valuable feedback on our Robotaxi service.

Based on Tesla’s message, it appears that participation in the service would be strictly invite-only for now. Participants must also download Tesla’s dedicated Robotaxi App to hail a ride. Rides can also be requested and initiated to and from any location within a geofenced area of Austin.

The robotaxi service will be available from 6:00 AM to 12:00 AM, seven days a week, though these hours may change depending on factors such as inclement weather. Interestingly enough, Tesla is inviting the first participants of the Robotaxi program to share photos and videos of their experience with the service.

While the vehicles themselves are autonomous and would operate without human input, the Robotaxis would still be accompanied by a Tesla staff member to monitor the vehicle. This strategy suggests that Tesla is really putting safety above all in its initial Robotaxi rollout.

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