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SpaceX Starship factory aiming to build five megarockets in 2023
CEO Elon Musk says that SpaceX’s South Texas Starship aims to build up to five of the two-stage megarockets in 2023.
SpaceX’s Boca Chica, Texas hardware endeavors began in an empty field in late 2018, kicking off Starhopper testing in 2019. In late 2019 and early 2020, the company began building the bones of the factory that exists today, relying heavily on several giant tents (“sprung structures”) similar to those used by Tesla. SpaceX has already begun the process of replacing those tents with larger, permanent buildings, but two of the original tents continue to host crucial parts of the Starship manufacturing process.
In terms of useful output, that manufacturing slowed down a bit in 2022. That slowdown can likely be partially explained by the need to move equipment and processes into the first finished section of Starfactory. But in general, SpaceX was simply focused on finishing and testing Starship S24 and Super Heavy B7 – both stages of the latest vehicle meant to attempt Starship’s first orbital launch.
Only by late 2022 did Ship 24 more or less complete proof testing, and Booster 7 is still several major tests away from solidifying full confidence in its design. SpaceX has only conducted limited testing with fully-stacked Starships, further reducing the amount of confidence the company can have in the assembled rocket. Lacking the data needed to know with certainty whether the tweaked designs of Starship and Super Heavy are good enough for several orbital test flights, it’s thus unsurprising that SpaceX only produced a handful of usable ships and boosters in 2022.
The update that's rolling out to the fleet makes full use of the front and rear steering travel to minimize turning circle. In this case a reduction of 1.6 feet just over the air— Wes (@wmorrill3) April 16, 2024
But if CEO Elon Musk’s forecast is correct, the company has plans to increase Starbase’s useful output in 2023. According to Musk, SpaceX aims to build “about five full stacks” this year, translating to five flightworthy Starships and five Super Heavy boosters.
In 2022, SpaceX finished Booster 7 and built Booster 8, Booster 9, and most of Booster 10. Booster 8 was almost immediately relegated to the retirement yard. Booster 9, featuring some significant design changes, completed a limited amount of proof testing and returned to the factory in early January – likely for Raptor engine installation. The fate of Booster 10 is unclear, but it stands as a prime example of how fast SpaceX can actually build massive Starship hardware when conditions are right. SpaceX began stacking B10 in late October 2022 and the vehicle is just two stacks away from full height three months later.
In the same period, SpaceX finished and immediately retired Starship S22, finished and began testing Ship 24, finished and began testing Ship 25, and finished stacking Ship 26. Booster 9’s upgrades partially insulate it from the most disappointing possible scenario, retirement before flight. Even if Booster 7 fails during prelaunch testing or its launch attempt, revealing major design flaws, it’s possible that Booster 9’s changes have already addressed those weaknesses, allowing it to continue the flight test campaign. Ship 25’s fate is even more dependent on the fate of Ship 24.
In 2022, SpaceX ultimately produced two “full stacks,” with a third (S26/B10) likely to be completed – albeit with a less certain fate – in early 2023. Delivering five full stacks this year – meaning five ships and five boosters that make it far enough to be paired with another and fully stacked – would be a major improvement. However, as was the case in 2022, higher-volume production will remain a risky proposition until the designs of the vehicles being built have been fully qualified.
Given how long it’s taken SpaceX to partially qualify Super Heavy Booster 7, it appears that the largest source of uncertainty will remain for at least another month or two, if not well into mid-2023. Starship production has many uncertainties of its own, and all of them are complicated by not knowing if a Super Heavy booster will be available to launch each new ship in a timely fashion.
Ultimately, an entirely different constraint means that “five full stacks” may be all SpaceX needs to build for the next 12+ months. After a long and painful process, the FAA completed an environmental review of SpaceX’s Starbase, Texas facilities, permitting a maximum of five orbital (full-stack) Starship launches per year. Starship’s FAA orbital launch license, which has yet to be granted, could be even more restrictive. A second Starship pad under construction in Florida is unlikely to be cleared for orbital launches until Starship has proven itself to be moderately safe in South Texas, which could easily take 12-18 months, if not longer.
Combined with the fact that no super-heavy-lift rocket in history has flown five times in its first year of launch activity, a trend Starship seems unlikely to break, SpaceX could practically halt production entirely in 2023 and still have a full year of testing ahead of it while only using Ships 24-26 and Boosters 7, 9, and 10. Unintuitively, that bodes well for a busy 2023 of Starship test flights, as much of the hardware required for three flight tests is already close to completion or almost ready to begin preflight testing.
Tesla executive Lars Moravy appeared today in front of the U.S. Senate Commerce Committee to highlight the importance of modernizing autonomy standards by establishing a federal framework that would reward innovation and keep the country on pace with foreign rivals.
Moravy, who is Tesla’s Vice President of Vehicle Engineering, strongly advocated for Congress to enact a national framework for autonomous vehicle development and deployment, replacing the current patchwork of state-by-state rules.
These rules have slowed progress and kept companies fighting tooth-and-nail with local legislators to operate self-driving projects in controlled areas.
Tesla already has a complete Robotaxi model, and it doesn’t depend on passenger count
Moravy said the new federal framework was essential for the U.S. to “maintain its position in global technological development and grow its advanced manufacturing capabilities.
He also said in a warning to the committee that outdated regulations and approval processes would “inhibit the industry’s ability to innovate,” which could potentially lead to falling behind China.
Being part of the company leading the charge in terms of autonomous vehicle development in the U.S., Moravy highlighted Tesla’s prowess through the development of the Full Self-Driving platform. Tesla vehicles with FSD engaged average 5.1 million miles before a major collision, which outpaces that of the human driver average of roughly 699,000 miles.
Moravy also highlighted the widely cited NHTSA statistic that states that roughly 94 percent of crashes stem from human error, positioning autonomous vehicles as a path to dramatically reduce fatalities and injuries.
🚨 Tesla VP of Vehicle Engineering, Lars Moravy, appeared today before the U.S. Senate Commerce Committee to discuss the importance of outlining an efficient framework for autonomous vehicles:
— TESLARATI (@Teslarati) February 4, 2026
Skeptics sometimes point to cybersecurity concerns within self-driving vehicles, which was something that was highlighted during the Senate Commerce Committee hearing, but Moravy said, “No one has ever been able to take over control of our vehicles.”
This level of security is thanks to a core-embedded central layer, which is inaccessible from external connections. Additionally, Tesla utilizes a dual cryptographic signature from two separate individuals, keeping security high.
Moravy also dove into Tesla’s commitment to inclusive mobility by stating, “We are committed with our future products and Robotaxis to provide accessible transportation to everyone.” This has been a major point of optimism for AVs because it could help the disabled, physically incapable, the elderly, and the blind have consistent transportation.
Overall, Moravy’s testimony blended urgency about geopolitical competition, especially China, with concrete safety statistics and a vision of the advantages autonomy could bring for everyone, not only in the U.S., but around the world, as well.
Tesla launched a new configuration of the Model Y this week, bringing more complexity to its lineup of the vehicle and adding a new, lower entry point for those who require an All-Wheel-Drive car.
However, the broadening of the Model Y lineup in the United States could signal a somewhat uncomfortable reality for Tesla fans and car buyers, who have been vocal about their desire for a larger, full-size SUV.
Tesla has essentially moved in the opposite direction through its closure of the Model X and its continuing expansion of a vehicle that fits the bill for many, but not all.
Tesla brings closure to Model Y moniker with launch of new trim level
While CEO Elon Musk has said that there is the potential for the Model Y L, a longer wheelbase configuration of the vehicle, to enter the U.S. market late this year, it is not a guarantee.
Instead, Tesla has prioritized the need to develop vehicles and trim levels that cater to the future rollout of the Robotaxi ride-hailing service and a fully autonomous future.
But the company could be missing out on a massive opportunity, as SUVs are a widely popular body style in the U.S., especially for families, as the tighter confines of compact SUVs do not support the needs of a large family.
Although there are other companies out there that manufacture this body style, many are interested in sticking with Tesla because of the excellent self-driving platform, expansive charging infrastructure, and software performance the vehicles offer.
Additionally, the lack of variety from an aesthetic and feature standpoint has caused a bit of monotony throughout the Model Y lineup. Although Premium options are available, those three configurations only differ in terms of range and performance, at least for the most part, and the differences are not substantial.
Minor Expansions of the Model Y Fail to Address Family Needs for Space
Offering similar trim levels with slight differences to cater to each consumer’s needs is important. However, these vehicles keep a constant: cargo space and seating capacity.
Larger families need something that would compete with vehicles like the Chevrolet Tahoe, Ford Expedition, or Cadillac Escalade, and while the Model X was its largest offering, that is going away.
Tesla could fix this issue partially with the rollout of the Model Y L in the U.S., but only if it plans to continue offering various Model Y vehicles and expanding on its offerings with that car specifically. There have been hints toward a Cyber-inspired SUV in the past, but those hints do not seem to be a drastic focus of the company, given its autonomy mission.
Model Y Expansion Doesn’t Boost Performance, Value, or Space
You can throw all the different badges, powertrains, and range ratings on the same vehicle, it does not mean it’s going to sell better. The Model Y was already the best-selling vehicle in the world on several occasions. Adding more configurations seems to be milking it.
The true need of people, especially now that the Model X is going away, is going to be space. What vehicle fits the bill of a growing family, or one that has already outgrown the Model Y?
Not Expanding the Lineup with a New Vehicle Could Be a Missed Opportunity
The U.S. is the world’s largest market for three-row SUVs, yet Tesla’s focus on tweaking the existing Model Y ignores this. This could potentially result in the Osborne Effect, as sales of current models without capturing new customers who need more seating and versatility.
Expansions of the current Model Y offerings risk adding production complexity without addressing core demands, and given that the Model Y L is already being produced in China, it seems like it would be a reasonable decision to build a similar line in Texas.
Listening to consumers means introducing either the Model Y L here, or bringing a new, modern design to the lineup in the form of a full-size SUV.
Elon Musk
Elon Musk reiterates Tesla Optimus’ most sci-fi potential yet
Musk shared his comments in a series of posts on social media platform X.
Elon Musk recently reiterated one of the most ambitious forecasts for Tesla’s humanoid robot, Optimus, stating it could become the first real-world example of a Von Neumann machine. He also noted once more that Optimus would be Tesla’s biggest product.
Musk shared his comments in a series of posts on social media platform X.
Optimus as a von Neumann machine
In response to a post on X that pondered on sci-fi timelines becoming real, Musk wrote that “Optimus will be the first Von Neumann machine, capable of building civilization by itself on any viable planet.” In a separate post, Musk wrote that Optimus will be Tesla’s “biggest product ever,” a phrase he has used in the past to describe the humanoid robot’s importance to the electric vehicle maker.
A Von Neumann machine is a class of theoretical self-replicating systems originally proposed in the mid-20th century by the mathematician John von Neumann. In his concept, von Neumann described machines that could travel to other worlds, use local materials to create copies of themselves, and carry out large-scale tasks without outside intervention.
Elon Musk’s broader plans
Considering Musk’s comments, it appears that Optimus would eventually be capable of performing complex work autonomously in environments beyond Earth. If Optimus could achieve such a feat, it could very well unlock humanity’s capability to explore locations beyond Earth. The idea of space exploration becomes more than feasible.
Elon Musk has discussed space-based AI compute, large-scale robotic production, and the role of SpaceX’s Starship in transporting hardware and materials to other planets. While Musk did not detail how Optimus would fit with SpaceX’s exploration activities, his Von Neumann machine comments suggest he is looking at Tesla’s robotics as part of a potential interplanetary ecosystem.
Tesla exec pleads for federal framework of autonomy to U.S. Senate Committee
Tesla Model Y lineup expansion signals an uncomfortable reality for consumers
