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SpaceX Starship factory breaks ground on an even bigger ‘high bay’

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SpaceX appears to have more or less broken ground on a new, even bigger ‘high bay’ assembly facility at its Boca Chica, Texas Starship factory.

Barely one year ago, SpaceX erected the first prefabricated steel sections of what eventually become its Starship factory ‘high bay’ – a spartan 81m (~265 ft) tall designed at the most basic level to shield final Starship and Super Heavy booster assembly from the elements. Situated near the southernmost tip of Texas and just a few miles west of the Gulf of Mexico, those “elements” can be less than pleasant at SpaceX’s primary Starship factory, ranging from sauna-like heat and humidity and mosquitoes the size of quarters to regular downpours, thunderstorms, tropical conditions, and even hurricanes.

While a great deal of work at Starbase is still done out in the open with little more than an umbrella as protection, SpaceX has nevertheless worked to find a middle ground where the most sensitive work (mainly structural welding) can be mostly shielded from wind and rain. First, SpaceX built a (relatively) tiny ‘windbreak’ too small for much of anything. Two years later, the windbreak is partially used for Starship nose section assembly – when a nose cone is stacked on and welded to a separate stack of four steel rings.

A few months after the triangular windbreak was fully finished, SpaceX started work on a larger box-like building that would eventually be known as the Starship factory’s ‘midbay.’ Standing around 45m (~150 ft) tall, the midbay was designed to support the process of assembling Starship tank sections from several stacks of 2-4 steel rings but was – for whatever reason – left too short to support the full Starship assembly process.

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Instead, once Starship tank sections were finished, they would have to be rolled out of the midbay for nose installation. Eventually, in July 2020, SpaceX began assembling an even larger ‘high bay’ that would ultimately measure 81m (~265 ft) tall and 20-25m (65-80 ft) wide and deep – easily big enough to fit the company’s existing Falcon 9 or Falcon Heavy rockets with room to spare. More importantly, of course, the high bay was built to be large enough to support Super Heavy assembly from start to finish, giving SpaceX teams a sheltered place to build the largest rocket boosters in history.

As of August 2021, SpaceX’s midbay has supported the assembly of 10 Starship prototypes, 5-6 propellant storage tanks, and several ‘test tanks,’ while the newer high bay has helped SpaceX build three (mostly) complete Super Heavy boosters in 2021. However, working at full speed, SpaceX’s midbay is really only capable of supporting the assembly of one Starship tank section (and more general work on two) at a time and the high bay – while offering at least twice the covered surface area – appears to be limited to simultaneous work on two or three different stacks (boosters, ships, tanks, etc.).

As SpaceX slowly but surely treks towards the end of approximately two years almost exclusively dedicated to building ever-changing prototypes, it’s been clear for a while that the company would need to drastically expand its production facilities to produce the dozens of Starships and boosters CEO Elon Musk has been publicly dreaming of. Even at lower volumes, those existing facilities – while great for producing a dozen or more prototypes per year – would still become a chokepoint for the near-term production of a small fleet of operational Starships and Super Heavies.

In turn, Musk revealed that SpaceX was about to start building “a much larger high bay” adjacent to the existing structure in late July. On August 20th, a little over a year after assembly of the original high bay kicked off, SpaceX began the process of tearing up existing concrete for the even larger bay – breaking ground, at least in a sense. According to Musk, the newest addition to Starbase’s Starship factory will be about 10% taller (~90m vs 81m), substantially wider, and likely a bit deeper than the existing high bay, allowing for the installation of two side-by-side bridge cranes with tracks running the full width of the building.

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With at least 2-3 times more surface area than the high bay, the new wide bay should give SpaceX enough space to simultaneously assemble something like 4-8 Starships or Super Heavy boosters. Depending on which direction SpaceX goes, the wide bay could also potentially be large enough for SpaceX to create the first true Starship and Super Heavy assembly lines, though that would be a substantial departure from Starbase’s existing approach to manufacturing.

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 owner fixes common feature complaint with crafty DIY retrofit

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Credit: @mikegapinski

Tesla owners have long griped about the wireless phone charger in the Model Y and other vehicles. It often turns smartphones into miniature ovens rather than reliably topping them up.

Software engineer and Model Y owner Michał Gapiński tackled this issue head-on with a clever DIY upgrade, swapping the cooled wireless charger pad from the China-made Model YL in for the one that came standard in his vehicle.

There are several key differences between the U.S.-built Model Y’s wireless charging pad and the one that Tesla has been installing in the Model YL. The one installed in U.S.-built vehicles lacks active cooling and relies on basic heat dissipation, leading to rapid temperature buildup during charging. In contrast, the Model YL integrates a small fan for active cooling.

This design maintains lower temperatures even in warm ambient conditions, though it does not support faster Qi2 charging on iPhones. The connector matches exactly, making physical swaps feasible on compatible consoles, but coding is required to enable full functionality.

Owners in the U.S. have complained about the wireless charging pad, with many reporting that overheating is fairly common. Within 20 or 30 minutes of placing a phone on the wireless charging pad, many have reported overheating messages on their phones, which halt charging and essentially turn the pad into a fancy place to rest your phone.

Many owners have opted to simply plug their phones into a charging cord. Tesla has acknowledged the problem by releasing several solutions for owners, including a relatively new feature that allows you to simply turn off the charging and simply act as a holder for your phone while driving.

Gapiński said that he sourced the cooled pad affordably from China, and it cost under $200 for the part.

He removed the existing console charger, swapped in the new unit, confirming a perfect connector fit, and handled the trim differences. Since the parameter isn’t fully secured, he enabled it through custom coding outside official Toolbox.

The fan activates quietly, blending with AC and seat cooling. He reported the installation was effective and the wireless charging pad worked perfectly; it even kept the phone cool as it stayed at just 86 degrees Fahrenheit. Many times, the wireless charging pad will bring the phone’s temperature well above 100 degrees, sometimes even being relatively hot to the touch.

This retrofit highlighted an elegant, owner-driven solution to a factory shortcoming. It is expected that Tesla will begin installing the cooled charging pads into new cars in the U.S. soon, and hopefully, it will offer some sort of retrofit service or kit to owners here who want to use the charging pad effectively.

For those who love to tinker, it’s an accessible upgrade, proving that innovation thrives beyond the production line.

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Tesla exec says Roadster unveil is soon — for real this time

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(Credit: teslaindiafansclub/Instagram)

The Tesla Roadster unveiling could be coming “in a few weeks,” according to the company’s Chief Designer Franz von Holzhausen, who said at the Tesla Takeover Europe Event in Austria that the all-electric hypercar could finally make its way to the production line after years of anticipation.

Von Holzhausen delivered the news just days after The Information reported that Tesla planned to push the Roadster unveiling to August. It was slated for both April and May of this year, but now it seems the company is leaning toward a late Summer event to cap off the heat with perhaps its most anticipated vehicle of all-time.

Franz has been with Tesla since 2008, and has played a pivotal role in the iconic design language the company has utilized with its vehicles. Speaking to the crowd in Austria virtually, von Holzhausen’s comments injected fresh excitement into a project that has been plagued by delays for nine years.

The second-generation Roadster promises to redefine supercar standards. Tesla’s website still highlights ambitious targets: 0-60 mph in under 1.9 seconds (with optional SpaceX thruster pack potentially achieving 1.1 seconds or less), a top speed exceeding 250 mph, and a range of about 620 miles.

Equipped with a tri-motor all-wheel-drive setup delivering over 1,000 horsepower, the four-seater aims to blend blistering acceleration, everyday usability, and innovative features like cold gas thrusters for short-hop capabilities, technology that will combine the project with SpaceX.

But years after the company promised to start production, which was slated for 2020, the timeline for the Roadster has continued to shift.

Tesla has strung along those who have put $50,000 deposits down, as well as fans and enthusiasts of the company who have been long awaiting the company to bring forth a car truly designed for the human driver, and not autonomy. The Roadster is more than just a halo vehicle for Tesla; it showcases the company’s ability to push the boundaries while incorporating synergies from other Musk companies.

However, it has to make it to production, which is something Musk and Co. have pushed back repeatedly.

As Tesla navigates Robotaxi development and broader autonomy goals, the Roadster serves as a reminder of its performance roots. If von Holzhausen’s timeline holds, fans could witness this engineering marvel by late June or early July 2026. Whether a full unveiling, demo, or initial deliveries, it marks a milestone for electric supercars.

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Tesla Roadster unveiling gets pushed again, but new event details emerge

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Credit: Dan Burkland

Tesla has reportedly pushed the unveiling of the Roadster once again, but there are also evidently new details about the event that the company plans to show off.

The Information reported this morning that Tesla will now unveil, for the second time, the next-generation Roadster in August, a further delay from the multiple timeline that the company had previously stated.

The report has not been confirmed or denied by Tesla at any capacity.

It also states the unveiling event will take place in Texas, the same place that Tesla executives revealed in May would be the place of manufacture for the company’s highly-anticipated supercar, which boasts a top speed of over 250 MPH and 650 miles of range, according to its website.

Tesla is also expected to showcase the SpaceX package, which will be used for faster acceleration and potentially hovering capabilities, at the unveiling event, the report states. Musk has always planned for this to happen, but now it seems it is more realistic than ever

The Roadster has had its unveiling date and manufacturing date pushed back on many occasions. It was set to start production in 2020, but the COVID-19 pandemic crippled supply chain operations, forcing Tesla to push its timeline back considerably.

However, COVID has been over for some time, and Tesla has still not managed to successfully schedule and execute an unveiling event, which is something fans and enthusiasts, as well as those who have put down a $50,000 deposit, have been waiting for.

The vehicle was close to completion last year, but Musk truly wanted Lars Moravy and Franz von Holzhausen to push the limits of the Roadster. In July of last year, Moravy said:

“Roadster is definitely in development. We did talk about it last Sunday night. We are gearing up for a super cool demo. It’s going to be mind-blowing; We showed Elon some cool demos last week of the tech we’ve been working on, and he got a little excited.”

It is important to note two things: Tesla has not confirmed these details, and the company has regularly pushed these dates back. Until Tesla sends out formal invitations with a concrete date, taking any unveiling event reports with a grain of salt is a good idea.

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