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SpaceX Starship factory churning out new rocket parts with Elon Musk's help

Elon Musk has posted the first official glimpse inside SpaceX's newest Starship factory facilities. (Elon Musk)

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5 years ago

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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.

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.

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SpaceX’s first Starship test tank was built primary outside in the South Texas elements, just like Starship Mk1, but it did use improved welding techniques and a better dome design. (NASASpaceflight – bocachicagal)

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.

SpaceX transports Starship hardware about a mile down the road from its manufacturing center to a dedicated test stand and (soon) launch pad. (NASASpaceflight – bocachicagal)

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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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 Model Y seen testing under wraps in India ahead of launch

Tesla appears to be getting closer to launching vehicle sales in India, as a few wrapped Model Y units have recently been spotted.

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20 hours ago

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April 20, 2025

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Following years of back and forth between Tesla and the Indian government, the automaker is finally expected to launch sales in the country in the coming months, and one of the company’s vehicles was spotted testing over the weekend.

On Sunday, a privacy-wrapped Model Y was seen driving in India and was posted on Reddit, as Tesla prepares to debut vehicle sales in the country for the first time. The news comes a little over a month after Tesla began certifying the Model Y and Model 3 for sale in the country, and as the U.S. manufacturer gets ready to launch the nation’s first store in Mumbai.

The appearance of the refreshed Model Y comes just a few days after another recent sighting in the country, in which a wrapped unit was seen driving on the Mumbai Pune Express Way.

Credit: shameelck | Reddit

READ MORE ON TESLA INDIA: Elon Musk, President Trump share interesting dialogue regarding Tesla Gigafactory India

Tesla’s vehicles can regularly be seen under privacy wraps such as this one ahead of their launch, often with the company’s vehicles before they’re officially unveiled. As such, many have speculated following the sighting that Tesla could either be preparing to launch the RWD variant launched in some markets in recent weeks, or the Performance version of the SUV, which is widely expected to debut sometime this year.

According to local reports, Tesla also signed a five-year lease on Mumbai store at the Bandra Kurla Complex, while a second store is expected to open near the New Delhi airport at Aerocity. Meanwhile, Tesla has also been hiring for the stores in recent months, along with holding a recruitment day in Mumbai last month.

Much of the delay on Tesla’s entry into India came from the country’s high import tariffs on vehicles and other products, while one of the government’s conditions for the country selling cars there was to utilize local suppliers. Last month, a rumor started circulating suggesting that Tesla was partnering with automotive company Tata Group for the local production of components such as castings, forgings, electronics, and more.

Tesla India: Thousands of cars set to hit Mumbai in coming months, claims report

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Tesla doubles down on Robotaxi launch date, putting a big bet on its timeline

Tesla continues to double down on its June goal to launch the Robotaxi ride-hailing platform.

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3 days ago

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April 18, 2025

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Credit: Tesla

Tesla has doubled down on its potential launch date for the Robotaxi ride-hailing platform, which will utilize the Cybercab and other vehicles in its lineup to offer driverless rides in Austin, Texas.

Tesla said earlier this year that it was in talks with the City of Austin to launch its first Robotaxi rides, and it planned to launch the platform in June.

This has been a widely discussed timeline in the community, with some confident in the company’s ability to offer it based on the progress of the Full Self-Driving suite.

However, others are skeptical of it based on Tesla’s history of meeting timelines, especially regarding its rollout of FSD.

Nevertheless, Tesla was asked when it would be able to offer Robotaxi rides and where, and it clearly is not backing down from that June date:

It is getting to a point where Tesla is showing incredible confidence regarding the rollout of the Robotaxi in June. We have not seen this kind of reiteration regarding the rollout of something regarding autonomy from Tesla at any point in the past.

CEO Elon Musk has even been increasingly confident that Tesla will meet its target. Earlier this week, he said the vehicles will be able to roll off production lines and drive themselves straight to a customer’s house:

Elon Musk continues to push optimistic goal for Tesla Full Self-Driving

There could be some discussion of an acceptable grace period, as the timeline for the Robotaxi rollout could still be considered a success, even if it were a month or two late. However, if it were pushed back further into 2025 or even 2026, skepticism regarding these timelines would continue to persist.

As of right now, it seems Tesla is extremely confident it will meet its goal.

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Tesla Semi fleet from Frito-Lay gets more charging at Bakersfield factory

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3 days ago

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April 18, 2025

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Tesla Semis showcased at Frito-Lay plant in Modesto, CA
Frito-Lay transformed its Modesto, Calif., site by replacing diesel fleet assets with ZE and NZE alternatives and installing fueling and charging infrastructure for the new fleet as well as on-site renewable energy generation and storage.

Among the several companies that have had the opportunity to add Tesla Semi all-electric Class 8 trucks to their fleets earlier than others, the most notable is arguably Frito-Lay, which has utilized the vehicle for a couple of years now.

However, as their fleet is making more local runs and there are undoubtedly plans to expand to more Semi units, the company has recognized it needs additional Megachargers to give juice to their trucks.

As a result, Frit-Lay decided to build more chargers at their Bakersfield, California facility, according to new permits filed by Tesla:

There are already chargers at the company’s Modesto, California, factory, but Bakersfield is roughly three hours south of Modesto.

Interestingly, Tesla is calling the chargers “Semi Chargers” in the filing, potentially hinting that it is no longer referring to them as “Megachargers,” as they have been in the past. This is a relatively minor detail, but it is worth taking note of.

In 2022, Frito-Lay began installing these chargers in preparation for the Semi to become one of the company’s main logistics tools for deliveries in California and surrounding states.

Frito-Lay is not the only company that has chosen to utilize the Tesla Semi for these early “pilot” runs. PepsiCo has also been a company that has used the Semi very publicly over the past two years.

Additionally, the Tesla Semi participated in the Run on Less EV trucking study back in late 2023, where it managed to complete a 1,000-mile run in a single day:

Tesla Semi logs 1,000-mile day in Run on Less EV trucking study

Tesla is planning to ramp production of the Semi late this year. On the Q4 2024 Earnings Call, VP of Vehicle Engineering Lars Moravy said the company would be focusing on the first builds of the Semi’s high-volume design late this year before ramping production in the early portion of 2026:

“We just closed out the Semi factory roof and walls last week in Reno, a schedule which is great with the weather. In Reno, you never know what’s going to happen. But we’re prepping for mechanical installation of all the equipment in the coming months. The first builds of the high-volume Semi design will come late this year in 2025 and begin ramping early in 2026.”

Tesla will build these units at a new Semi production facility located in Reno near its Gigafactory. The company is getting closer to finishing construction, as a drone video from this morning showed the facility is coming along at a good pace:

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