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SpaceX Starship factory churning out new rocket parts with Elon Musk's help
SpaceX’s South Texas team of Starship engineers and technicians – including CEO Elon Musk himself – are working around the clock to manufacture hardware that will likely become the company’s next Starship prototype in the near future.
Over the last few days, SpaceX has made quick progress churning out shiny steel rings and wrapping up propellant tank domes – the next round of full-scale Starship hardware. To better build the first flight and orbit-capable prototypes, not to mention hundreds or even thousands of Starship spacecraft and Super Heavy boosters in the years to come, SpaceX teams and contractors have spent the last two months aggressively expanding the company’s Boca Chica, Texas facilities. In fact, the very same company that built Tesla’s newest tent-based Model 3 assembly line – Sprung Instant Structures – has erected part of a massive, new Starship factory.
Finally giving the company’s grizzled South Texas team a large, climate-controlled space to work from, CEO Elon Musk has also been spending more and more time at SpaceX’s upgraded Boca Chica facilities. Most recently, the executive gave Twitter followers the first official glimpse inside one of the new Starship production tents, revealing several giant spacecraft parts in various stages of completion. It’s currently unclear what the destiny of that new Starship hardware will be, but a few recent clues seem to point in one specific direction.
Yeah, we just finished two more propellant domes. SpaceX team & supporting suppliers are doing amazing work ramping Starship production.— Elon Musk (@elonmusk) January 22, 2020
On January 10th, SpaceX intentionally – and largely successfully – ‘popped’ a Starship propellant tank to determine the quality of partially-upgraded manufacturing and assembly techniques. Built in just two weeks, Musk revealed shortly after the test that the baby Starship tank – filled with water – had made it to 7.1 bar (103 psi) before bursting.
While fairly meaningless on its own, it apparently means that the test tank survived well past the pressures Starships will need for orbital flight, although it only managed a safety margin of ~18%. To be fully flightworthy, Musk says that SpaceX wants Starship tanks to survive pressures of at least 8.5 bar (125 psi) – a margin of ~40% – before it considers the giant spacecraft safe enough for humans.
Given that the 7.1 bar the test tank reached is more than enough to support “orbital flight”, albeit with a less-than-optimal safety margin, it would be reasonable to assume that SpaceX would choose to immediately green-light the first flightworthy Starship spacecraft, deemed SN01 (serial number 01) by Musk. While that first prototype would thus be unable to launch humans and fulfill its ultimate goal as a Starship, it would give SpaceX experience building a second full-scale prototype (following Mk1) and give the company time to gradually upgrade its production facilities and manufacturing hardware.
Musk sketched out a number of possible improvements even before SpaceX tested its miniature Starship tank to destruction, indicating that “more precise parts” and an enclosed, wind-protected welding shop should be enough to raise Starship’s safety margin to ~40%. A step further down the road, Musk raised autogenous laser welding as a possibility for future production upgrades, although the advanced welding method would require a truly controlled environment and much more precise parts and manufacturing hardware.
In the last 24 hours, SpaceX has filed for a number of road closures for the highway adjacent to its Boca Chica Starship facilities, a sign that some form of rocket hardware transport and testing is imminent. As such, it now seems much more likely that SpaceX has decided to spend at least a few more weeks building and testing a second (and possibly a third) Starship tank prototype before kicking off the production of the next full-scale rocket.
Intriguingly, SpaceX has also received several large shipments of liquid nitrogen (LN2), a neutral cryogenic fluid often used to simulate cryogenic propellants without risking a massive explosion or fire. That LN2 wont last forever in SpaceX’s storage tanks, confirming that some form of cryogenic testing is imminent. The most likely explanation is that SpaceX is in the late stages of manufacturing a second tank prototype, soon to be shipped about a mile down the road to the company’s nearby test and launch facilities.
If SpaceX is planning to perform a burst test with liquid nitrogen, it will likely be quite the spectacle – much closer to Starship Mk1’s spectacular failure than the milder demise of the first miniature Starship tank. SpaceX has roadblocks scheduled every day for the rest of the week, so stay tuned to find out when exactly Starship’s next big test is expected.
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SpaceX set to launch astronauts and a classified Falcon Heavy mission on the same day
SpaceX plans three launches Thursday, including Crew-13 astronauts and Falcon Heavy’s first classified NRO mission.
SpaceX is lining up one of the busiest single days in its history, and the company offered a preview on Wednesday morning with a simple post on X: “Sunrise at pad 40.” The video and photos show Falcon 9 standing at Space Launch Complex 40 at Cape Canaveral, roughly a day before it is scheduled to carry four astronauts to the International Space Station.
That launch is only the first of three SpaceX missions planned for Thursday, October 1, across both coasts.
Sunrise at pad 40 pic.twitter.com/J7Qme4VvIX
— SpaceX (@SpaceX) September 30, 2026
Crew-13 is targeting liftoff at 11:10 a.m. ET, with a backup opportunity Friday at 10:47 a.m. ET. NASA astronaut Jessica Watkins will command the mission, with NASA’s Luke Delaney as pilot and Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov serving as mission specialists. According to NASA, Dragon is set to dock with the forward port of the station’s Harmony module around 8 p.m. ET, less than nine hours after launch. Watkins is the only member of the crew who has flown before, and Kutryk will become the first Canadian to reach orbit through NASA’s Commercial Crew Program.
The Falcon 9 booster is flying for the third time after supporting Crew-12 and a Starlink mission, and it will attempt a landing at Landing Zone 40 beside the pad. That site made its debut in February when the Crew-12 booster touched down there, as Teslarati reported at the time. Crew-13 will relieve the Crew-12 astronauts, who have been aboard the station since the middle of February.
On the West Coast, another Falcon 9 is scheduled to lift off from Vandenberg Space Force Base in a window running from 2:18 to 3:16 p.m. ET, a flight NASASpaceflight lists as a Transporter rideshare mission.
The day is set to close at 11:53 p.m. ET, when Falcon Heavy launches from Launch Complex 39A with NROL-97, the first National Reconnaissance Office payload ever to fly on the rocket. SpaceX rolled the vehicle out to the pad Tuesday night. Its two side boosters, which previously flew GOES-U, ViaSat-3 F3 and NASA’s Roman Space Telescope, will return to Landing Zones 1 and 2, while a new center core will be expended in the Atlantic. The Roman launch took place on August 30, so NROL-97 will come barely a month later as Falcon Heavy’s third flight of 2026 and 14th overall.
NASA taps SpaceX to launch the telescope that could unlock new worlds
If all three Florida boosters land as planned, it would be the first time the Space Coast has seen landings at LZ-40, LZ-1 and LZ-2 on the same day, according to the Orlando Sentinel, which has warned residents in Brevard, Orange and Volusia counties that more than one sonic boom is possible.
The schedule arrives just three days after Starship reached orbit for the first time on Flight 14 from Starbase, Texas, deploying 26 Starlink V3 satellites. If Thursday’s missions stay on time, SpaceX will have flown Starship, Falcon 9 and Falcon Heavy from four different pads in about four days.
Crew-13 is also the start of a longer run for Dragon. NASA recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification, keeping Dragon as the agency’s only operational ride to the station while Boeing’s Starliner remains grounded.
Although the two vehicles are built for completely different use cases, Tesla utilized engineering expertise while developing both the Cybercab and Semi to build a thermal architecture that would fit both vehicles. Of course, with some slight revisions.
The development was noted by Lars Moravy and Dan Priestley last week at Tesla’s Semi Handover event in Sparks, Nevada, where the company showed off its dedicated production facility for the Class 8 truck.
🚨 Tesla designed the integrated thermal systems for Cybercab and Semi at the same time as the vehicles were both in development
Tesla wanted to build one thermal system that worked with both vehicles, apart from small modifications.
Semi and Cybercab share parts 🤯 pic.twitter.com/KmzSsUbrcg
— TESLARATI (@Teslarati) September 25, 2026
Tesla’s decision to develop one thermal architecture for both the Cybercab and Semi is one of the more revealing engineering choices in the company’s 2026 lineup:
“We designed it at the same time we designed the Cybercab and we said okay we’re going to take our most efficient vehicle and our biggest vehicle and we’re going to take one thermal system and make it work for both.”
Core parts, meaning the compressor, pumps, and heat exchangers, are shared, with only modest changes to cooling-loop sizing and a larger radiator on the truck. The result, they said, is a compressor and thermal stack already proven across millions of miles, delivering “reliability from day one.”
Priestley also highlighted a practical payoff of the indirect design:
“There’s no AC lines, there’s no refrigerant lines…It comes from the factory fully charged, sealed with refrigerant, and it just exchanges coolant. It doesn’t actually run refrigerant up to the front of the vehicle.”
This eliminates potentially leak-prone plumbing that would otherwise require hands-on service, reducing overall uptime and potentially cutting into business margins. The megamanifold runs cabin HVAC and every powertrain heating and cooling loop at once, recapturing waste heat from motors and the battery instead of dumping it the way a diesel engine does.
The approach is just the latest chapter in a continuing story of stretching thermal solutions across wildly different vehicles. Model Y’s Octovalve evolved into the Super Manifold used on Cybertruck, and later Model S/X refreshes. Cybercab then introduced Supermanifold V3, which Tesla says is 80 percent automated to build and 38 percent more efficient than typical automotive thermal systems.
This thermal system is also shared with Cybercab – one thermal system for both our most efficient vehicle & our biggest vehicle
— Tesla Semi (@tesla_semi) September 25, 2026
Tesla has done the same with the 4680 cells, both being utilized in the Cybertruck and Semi, and with heat-pump compressors that Priestley noted were already common across the passenger-car fleet.
Concurrent development of crucial vehicle elements buys scale and reliability that a truck-only thermal system could not match. High-volume passenger car parts are cheaper and more accessible, which can give fleets a sealed, low-maintenance loop of operation from their first day of operation.
For owners and operators, that translates into less energy spent on cabin heat in the colder months, fewer refrigerant-related repairs, and a thermal architecture already stress-tested at passenger-car volumes before the first high-volume Semi left the lines in Nevada.
Tesla CEO Elon Musk certainly tipped off some details of the Tesla Roadster event with a broadening of information regarding the company’s decision to delay the unveiling for two weeks.
For years, people have speculated about what the Roadster will be capable of. While there have been plenty of things said about what it *could* do, we have not seen or been told by Tesla what it will actually be capable of.
However, over the past few days, Tesla’s weather updates have truly pushed the speculation into Plaid Mode, basically all but confirming the car will have some sort of aerial capability — whether that would be hovering or fully flying remains to be seen — but it definitely seems that it will be able to leave the ground intentionally.
“Because this event can only be held outdoors…”
Tesla posted on Monday that it would delay the Roadster event until October 15, and it indicated that it had to do this because the event “can only be held outdoors.”
With the potential SpaceX collaboration to develop cold-gas thrusters that will help the vehicle go airborne, doing this indoors is probably not a safe, or even plausible, possibility.
Roadster event update
We’ve been tracking the weather closely with local meteorologists, but given the severe conditions predicted & because this event can only be held outdoors, we’ve made the difficult decision to reschedule.
New date is October 15. Additional details to…
— Tesla (@Tesla) September 28, 2026
FAA Airspace Restriction
The FAA gave Tesla a Temporary Flight Restriction (TFR) for 10,000 feet above ground level, much higher than the typical 2,000-foot restrictions that are usually placed at SpaceX’s McGregor, Texas site.
Tesla Roadster event requires restricted airspace, and the FAA obliges
Some have said that this massive increase is due to Tesla’s need to restrict unauthorized drone use for spying on the event.
Elon Admits High Winds
“Due to high winds, the new Roadster demo is postponed by 2 weeks,” Musk said in a post on X yesterday.
Due to high winds, the new Roadster demo is postponed by 2 weeks https://t.co/dV3ojDh1iT
— Elon Musk (@elonmusk) September 30, 2026
A reply reading, “What’s strong wind got to do with a car demo with four grounded wheels?” was directly below Musk’s post, satirically and sarcastically probing for more details.
All signs are pointing toward an aerial demonstration for the Roadster.
SpaceX set to launch astronauts and a classified Falcon Heavy mission on the same day
Tesla Cybercab and Semi have more in common than you might think
