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Elon Musk teases expendable version of SpaceX’s reusable Starship rocket

(SpaceX)

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SpaceX CEO Elon Musk says that the company could eventually develop an expendable version of its next-generation Starship rocket.

Starship is extraordinarily ambitious. Even before considering the unproven concepts of orbital propellant refilling and full, rapid reusability that are central to the full system, Starship is a beast. The rocket measures 120 meters (~390 ft) tall and is theoretically capable of producing up to 7590 tons (~16.7M lbf) of thrust at sea level. It’s larger, taller, heavier, and more powerful than any other launch vehicle in history. 33 Raptor 2 engines power Starship’s Super Heavy booster – also more than any other rocket.

Once optimized, SpaceX says that Starship can launch up to 150 tons (330,000 lbs) to low Earth orbit while still recovering the orbital ship and suborbital booster for reuse. CEO Elon Musk has stated that Starship reuse will eventually take hours, enabling multiple flights per day for each ship and booster and dropping the marginal cost of each launch to just a few million dollars.

In comparison, SpaceX’s workhorse Falcon 9 rocket uses simpler Merlin 1D engines, has just 10 of those engines to Starship’s 39 Raptors, produces about 10 times less thrust at liftoff, and can launch about 11% as much payload to orbit while expending its upper stage. Even then, Musk reported in mid-2020 that the marginal cost of a Falcon 9 launch was $15 million – impressively low but still a vivid demonstration of just how far Starship has to go.

Starship’s orbital upper stage is roughly the size (and far heavier and more powerful than) as an entire two-stage Falcon 9 rocket. (BocaChicaGal/Richard Angle)

Simply ensuring that Starship can reach orbit at all is a major challenge. Successfully recovering Starship and Super Heavy after the fact may be an even bigger challenge and cannot be fully demonstrated until the rocket can consistently reach orbit. SpaceX won’t be able to reuse Starship until it can consistently recover ships and boosters from orbital launches. And there’s no guarantee that early prototypes will be reusable even if they’re recovered.

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Until reusability is demonstrated, every “Starship upper stage” will be functionally expendable whether or not Elon Musk wants it to be. Musk likely means that SpaceX may or may not decide to develop a Starship upper stage custom-built for expendable missions. Such a stage would likely take Starship, remove everything extraneous, and reduce its mass as much as possible. Musk has proposed something similar before, noting that SpaceX could develop a “lightened” version of Starship “with no heat shield or fins/legs” for expendable, interplanetary launches.

While SpaceX is closer than ever, it has still never attempted an orbital Starship launch or reused a Starship. (SpaceX)

Further to the contrary, SpaceX’s Starbase factory is already building multiple intentionally-expendable Starships. Ship 26 and Ship 27 feature no thermal protection, have no heat shield tiles, and will not be fitted with flaps, making them impossible to recover or reuse. More likely than not, they will be used to test other crucial Starship technologies like orbital refilling and cryogenic fluid management.

Meanwhile, SpaceX’s multibillion-dollar contract to use Starship to return NASA astronauts to the Moon revolves around a depot ship variant that will store propellant in orbit and cannot return to Earth. The first few Starship Moon landers may also be functionally expendable and only used for one astronaut landing apiece. In short, SpaceX already has extensive plans to build variants of Starship that are either fully expendable or can only be reused in orbit.

The Starship variants required for SpaceX’s NASA Moon landing contracts.

Single-use Starships

In early 2023, SpaceX updated the Starship section of its website, revealing that an expendable version of the rocket will be able to launch up to 250 metric tons (~550,000 lbs) to low Earth orbit in a single launch. Saturn V, the next most capable expendable rocket, could launch up to 118 tons (~260,000 lbs) to LEO and cost $1-2 billion per launch. SpaceX publicly advertising the expendable performance of Starship unsurprisingly confirms that the company is considering all of the capabilities its new launch system will offer.

And Starship’s expendable capabilities are significant. Constructed piece by piece over dozens of launches, the International Space Station weighs about 420 tons (~925,000 lbs). Two expendable Starships could launch more usable mass to LEO – truly revolutionary if SpaceX can make Starship launches frequent and routine.

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 Gigafactory Texas builds its half millionth vehicle

The milestone was shared via Twitter/X by the official @Gigafactories account.

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Credit: Tesla Manufacturing/X

Tesla’s Gigafactory Texas has officially rolled out its 500,000th vehicle, marking a significant achievement in the factory’s history and reinforcing its role as a central hub in Tesla’s vehicle manufacturing network. 

The milestone was shared via Twitter/X by the official @Gigafactories account. “Congratulations to the Giga Texas team for building 500k vehicles,” the company’s X post read.

As could be seen in Tesla Manufacturing’s post, the Gigafactory Texas team celebrated the milestone by posting for a photograph with the facility’s half millionth unit, a white Tesla Model Y. The team held balloons that spelled “500K” on its commemorative photo. 

Giga Texas, located near Austin, has ramped its operations since its launch, producing Tesla’s Cybertruck and Model Y. Crossing the half-million vehicle mark solidifies the facility’s importance to Tesla’s overall operations, especially considering the fact that the Model Y is the company’s best-selling vehicle.

While Giga Texas is just producing the Model Y and the Cybertruck for now, the facility is also poised to produce the Cybercab. The Cybercab is expected to be Tesla’s highest volume vehicle, with Elon Musk estimating that the company would be producing about 2 million units of the autonomous two-seater per year. 

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The Cybercab is unlike any vehicle that is currently produced today, and its production would be quite extraordinary. As per Elon Musk’s previous comments, the Cybercab’s manufacturing line would not look like an automotive production line at all. Instead, Musk noted that the Cybercab’s line in Gigafactory Texas would resemble a high-speed consumer electronics line instead.

“We do want to scale up production to new heights obviously with the Cybercab. Cybercab is not just revolutionary car design. It’s also a revolutionary manufacturing process. So I guess we probably don’t talk about that enough, but if you’ve seen the design of the Cybercab line, it doesn’t look like a normal car manufacturing line. It looks like a really high-speed consumer electronics line,” Musk previously stated.

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Tesla reportedly places large order for robot parts, hinting that Optimus V3 design is all but finalized

Tesla has reportedly placed a large order of linear actuators for humanoid robots from a Chinese supplier.

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Credit: Tesla

Tesla might have all but finalized the design for its Optimus V3 humanoid robot, at least if rumors from China prove accurate. As per recent reports, Tesla has reportedly placed a large order of linear actuators for humanoid robots from a Chinese supplier, with deliveries expected sometime in the first quarter of 2026.

The volume of orders suggested by the reports from China suggests that the components will not just be used for Optimus prototypes.

The rumor

As noted in a report from Sina News, media outlets across China have recently reported that Tesla has placed a $685 million (5 billion RMB) order for linear actuators from Sanhua Intelligent Controls. The components will reportedly be used for the production of Optimus, which will likely be mass-produced in its V3 iteration. The reports claimed that the delivery of the actuators will likely start sometime in the first quarter of 2026. 

Industry watchers have estimated that such a volume would be enough for about 180,000 Optimus robots. This suggests that while Tesla might not be able to start the initial production of its humanoid robots this year, the electric vehicle maker might be able to hit the ground running with its Optimus production next year. And as hinted at by Elon Musk’s comments on X, Tesla seems to be preparing to produce Optimus V3 en masse.

https://twitter.com/tslaming/status/1978311791890645146

Company comments

The reports of Tesla’s alleged actuator orders have resulted in Sanhua Intelligent Controls’ stock rising. Interestingly enough, a Tesla China representative has stated that “no official information about this order that could be disseminated externally.” A representative from Sanhua, on the other hand, simply stated that the company’s robotics business is progressing smoothly, but they could not comment on market rumors. 

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While these reports are rumors for now, there are some optimistic hints that Tesla might have all but finalized the design for Optimus V3, and the company might be looking to start the robot’s production. For one, Sanhua is already a Tesla supplier, providing components for the company’s electric cars. A report from The Information also alleged that Tesla is no longer looking to produce 5,000 Optimus robots in 2025. This was reportedly due to challenges in the robot’s hands.

If Tesla is really starting to order large volumes of components for Optimus’ production, it would suggest that the company might have overcome the challenges it was facing with the humanoid robot earlier this year. It would then not be farfetched if Tesla were able to start the initial production of Optimus V3 next year.

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Tesla eyes two new states for Robotaxi

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Credit: @TerrapinTerpene/X

Tesla has officially shown that it is eyeing two new states for Robotaxi operation in the U.S., as it hopes to add the new areas to its ever-growing list of places where the suite is either active or in the testing phase.

Tesla first launched its Robotaxi suite in Austin, Texas, in late June. It expanded the suite to the San Francisco Bay Area just a month later. Since then, it has not launched any public rides in any other states, but it has gained several approvals for early testing.

Tesla officially launches Robotaxi service with no driver

In preparation for operation in new states, Tesla routinely lists job postings on its Careers website, which helps align potential employees with opportunities ahead of regulatory approvals. This is a strategy that allows Tesla to start operations immediately upon licensing for testing.

Tesla started hiring Vehicle Operators for Autopilot in Arizona and Nevada months before the company gained any sort of approvals from state governments for Robotaxi. However, those approvals eventually came in the form of testing licenses, which allow the company to perform validation ahead of its public launch.

Tesla begins validating Robotaxi in a new area, hinting at expansion

Now, Tesla has posted job listings for Vehicle Operators for Autopilot in two new states: Colorado and Illinois. The Colorado job listing is located in Aurora, a suburb of Denver. Tesla is looking for Robotaxi operators in Chicago as well.

These postings hint toward Tesla’s continuing efforts to expand Robotaxi to new places. Earlier this year, CEO Elon Musk said the company would like to have Robotaxi available to at least half of the U.S. population.

It has expanded significantly since its initial launch in late June, but it is still a far way off from where Tesla would like it to be by year’s end.

So far, Tesla has job listings for Autopilot Vehicle Operators in Arizona, California, Texas, Florida, Colorado, Nevada, and Illinois.

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