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SpaceX Starship factory overflowing with new and flight-proven rockets

SpaceX has at least six separate Starship prototypes in work at its Boca Chica, Texas rocket factory. (NASASpaceflight - bocachicagal)

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After a relatively relaxed period of production and testing, SpaceX’s South Texas Starship factory is practically overflowing with new and flight-proven ships as the company prepares for the rocket’s next major tests.

Even before the one-off Starship Mk1 prototype failed a pressure test late last year, SpaceX was in the process of upgrading its Boca Chica production facilities and refining the ship’s design and manufacturing processes. Starship SN1, the first prototype built as part of that upgrade, rolled to the launch pad on February 25th, 2020, followed by Starship SN2 (turned into a test tank) just a week or so later. Starship SN3 and SN4 would both follow in early and late April, ultimately ending with the latter prototype’s spectacularly violent demise in late May.

Over the remaining three or so months, the pace of testing has slowed a bit as SpaceX’s Starship development program enters the full-scale flight testing phase. Starship SN5 began testing on July 1st, followed by SN6 around six weeks later. Both prototypes successfully hopped just 30 days apart. Now, although SpaceX still plans to hop SN5 a second time and may hop SN6 twice, too, the Starship program’s focus has shifted to high-altitude, high-velocity flight tests and the adoption of a new steel alloy.

Presumably in anticipation of a learning curve as that new steel alloy begins to be tested at full-scale for the first times, SpaceX is churning out Starship prototypes at an unprecedented pace. Intriguingly, that production ramp is hinged upon the assumption that a 304L-class steel alloy (compared to the 301 stainless steel used to build SN1 through SN6) will be as good or better than 301 steel in every significant way.

Currently, that assumption isn’t entirely baseless but is still built upon the success of Starship SN7, SpaceX’s first 304L test tank. SpaceX never confirmed its results but it’s believed that that test tank – more of a material demonstrator than an actual structural Starship prototype – surpassed all previous pressure records before it burst in June.

Starship test tank SN7, June 15th. (NASASpaceflight – bocachicagal
SN7 is believed to have broken pressure records before it burst on June 23rd. (NASASpaceflight – bocachicagal)
A second 304L test tank – Starship SN7.1 – rolled to the test site on September 7th. (NASASpaceflight – bocachicagal)

Given that SN7 performed quite well, it’s at least a bit less surprising that SpaceX is hinging months of work and at least four full-scale Starship prototypes on an otherwise unproven steel alloy. The next big test for 304L Starships will be a second test tank known as SN7.1. Rolled to the test site on September 7th, essentially as soon as Starship SN6 was safed and returned to the factory after its hop debut, SN7.1 is significantly more complex than its sibling and will test a ~304L Raptor mount (thrust puck) and skirt section. The forces and general conditions those new parts will be subjected to are substantially different than most of what SN7 was subjected to, meaning that there is a chance that 304L steel is less optimal in different scenarios.

With any luck, SN7.1’s test campaign – scheduled to begin as early as 9pm CDT (UTC-5), September 10th (today) – will be a flawless success, proving that SpaceX’s new steel alloy is universally superior to 301 for Starship-related applications. If that’s the case, Starship SN8 – the first full new-alloy prototype – will likely be fully outfitted with a nosecone and header tanks before beginning acceptance testing.

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SN8’s tank section (center) was fully stacked by late August. (NASASpaceflight – bocachicagal)
Alongside Starship tanks, SpaceX’s Boca Chica team has also been extensively prototyping upgraded Starship nose sections. Starship Mk1’s roughshod nose is visible for comparison on the far left. (NASASpaceflight – Nomadd)

Eventually, if SN7.1 aces its tests and SN8 performs well during preflight preparations, Starship SN8 could become the first prototype to launch with a full nose, header tanks, and flaps, as well as the first to fly with three Raptor engines. If Starship SN8 fails for any reason or is damaged during testing, though, it appears that SpaceX will have no shortage of ships built out of the same new steel alloy to choose from.

In just the last ten days, labeled parts and rings for Starships SN9, SN10, and SN11 have all been spotted, implying that SpaceX is concurrently building at least four new Starships. Notably, both Starships SN9 and SN11 already appear to have some of the studs needed for heat shield tile installation affixed to sections of their steel hulls. Based on the sheer number of steel ring stacks spotted over the last week, it’s also safe to assume that SN9’s tank section (and possibly SN10’s, too) is largely prefabricated.

Starship SN9’s common dome was sleeved with steel rings around August 15th. (NASASpaceflight – bocachicagal)
SN9’s aft dome and thrust puck was sleeved with steel rings around September 4th. (NASASpaceflight – bocachicagal)
Starship SN10’s thrust puck was delivered from Hawthorne, California on September 3rd. (NASASpaceflight – bocachicagal)
SN10’s forward dome was sleeved on September 8th. (NASASpaceflight – bocachicagal)
The first labeled Starship SN11 rings were spotted on September 9th. (NASASpaceflight – bocachicagal)
Two reinforced five-ring stacks will likely support nosecones on two new Starships. (NASASpaceflight – bocachicagal)

Assuming two of the in-work nosecones are ultimately meant for flight, SpaceX may already have enough hardware on hand to fully assemble two Starships (presumably SN8 and SN9) – including nosecones, header tanks, nose rings, and flaps. It’s safe to say that if SN7.1 achieves its goals, preparations for the first triple Raptor hop, 20 km (~12 mi) test flight, and skydiver-style landing attempt could come together incredibly quickly.

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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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Elon Musk

Elon Musk’s Grok can basically control anything in your Tesla now

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Credit: Tesla

Tesla’s 2026 Summer Update turns Grok from a talking companion into a true in-car controller, with considerably expanded capabilities. Where the assistant once answered questions and handled navigation, it can now operate hardware and software through ordinary speech, including several requests at the same time.

Grok has become incredibly robust over the past few quarters, and this new ability that Tesla has included with its Summer Update is perhaps the clearest sign of just how capable it has become.

You can issue many commands to Grok at once, and each will be taken care of: anything from headlight control to climate adjustments to mirror folding can now all be taken care of with a simple sentence spoken toward Grok:

Here’s another example I used in my Model Y:

Tesla’s official Release Notes list the core powers of Grok’s new capabilities: Grok can place phone calls from a paired phone, search a streaming service and queue music, adjust climate, and search the Controls panel. Drivers can also ask it questions about the vehicle or the latest features included in a recent software update.

It can also take care of driving settings, dynamics, and other relevant preferences that deal with how the car operates and handles.

Tesla Summer Update begins rolling out: a look at the new features

It’s also more of a use case than a novelty feature. Grok was great for learning about something that was being pondered while Full Self-Driving was taking care of the major automotive responsibilities, but it did have some useful functionality when it came to navigation.

Another less-noted improvement is the swift transition that Grok has from thinking of its answer to giving you one. In the past, it would take a few seconds for Grok to truly come up with a valuable response. It now seems that it is improving, at least slightly.

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Elon Musk

Tesla is fixing Full Self-Driving’s pothole problem

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Tesla Model Y L in a field
Credit: Tesla

Tesla Full Self-Driving is set to get a major fix with pothole avoidance, a feature that CEO Elon Musk said recently was “coming soon.” The feature has been included within the FSD v14 release notes for some time as an upcoming improvement.

Potholes come in all shapes and sizes, but one thing is universal about them, and that is the fact that every driver wants to avoid them. Driving into or over a pothole can cause tire and wheel damage, alignment issues, and even, in some more severe instances, injury to occupants or major damage to a vehicle in despair.

Tesla Cybercab uses a unique strategy for picking up the right rider

Musk said late last night in a post that pothole avoidance while utilizing the Full Self-Driving suite is “coming soon.”

Full Self-Driving, even in its most recent and robust forms, still has its shortcomings. While the suite has performed exceptionally well with avoiding on-road obstacles like cardboard boxes, horse droppings, car parts, and other debris, it still seems to struggle with recognizing certain things.

Potholes and other abrupt changes in a road’s layout are things that FSD still tends to struggle with. Perhaps the suite’s 3D modeling is still in need of some additional data or some sort of script that will help it to avoid a potentially destructive pothole or bump in the road that would be easily recognizable by the human eye.

Musk has mentioned pothole avoidance for some time, with the initial idea coming in April 2019 when an owner first requested the feature. Musk said that Tesla would “definitely” develop pothole avoidance.

In August 2020, Musk said Tesla was in the process of labeling bumps and potholes so cars can either slow down or steer around them altogether.

Tesla to utilize micro maps for pothole-detection in future update

Avoiding major disturbances in the road is a necessary feature for Full Self-Driving to have, especially as Tesla is working toward a fully autonomous program that will eventually allow every occupant in the vehicle to sleep, work, or enjoy leisure time while traveling.

That truly begins this week with the launch of Cybercab on Thursday.

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Elon Musk

Elon Musk says he knows how to save Earth for a billion years

Elon Musk says sentient AI satellites launched from the Moon could keep Earth livable forever.

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Elon Musk spent part of his weekend describing a plan to keep the planet livable for roughly a billion years, and it starts with satellites that can think for themselves.

In a post on X, Musk argued that swapping fossil fuels for solar and wind power will not be enough to protect humanity from what he called extremely severe extinction events, the kind that occur roughly every 100 million years. His fix is what he called sentient satellites, or solar-powered satellites, controlled by AI, that would sit in a fixed spot between Earth and the Sun after being launched off the Moon using a giant electromagnetic catapult instead of rockets.

The satellites’ onboard AI would make continuous, small adjustments rather than waiting on human instructions. The mass driver is Musk’s proposed way of getting the raw material there cheaply by using an electromagnetic launch track built on the Moon, where lower gravity and no atmosphere make it far easier to fling cargo into space than it is from Earth.

Musk shared a Grok generated estimate suggesting roughly 5 percent of Florida’s land, or about 1.68 million acres, could face regular flooding by 2070 under a high sea level rise scenario, and said humanity has about 50 years to act before coastal living looks very different than it does today.

This is not the first time Musk has floated the idea. He raised a similar concept in November, describing a solar powered AI satellite constellation that could make tiny adjustments to incoming sunlight to fine tune Earth’s temperature. Musk has also tied planetary risk to his broader vision at SpaceX, where his compensation package is explicitly linked to establishing a self-sustaining Mars colony, one he has described as an insurance policy against the kind of extinction event he referenced this weekend, and where he has said humans could set foot within five to seven years.

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