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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.

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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.

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 calls out viral claim of 10,000 Tesla Optimus deal: “Fake”

For now at least, Tesla seems determined to focus on the development of Optimus V3.

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Credit: Tesla Optimus/X

Elon Musk has provided some clarification to recent reports suggesting that PharmAGRI, a US pharmaceutical and agricultural infrastructure company, is looking to deploy 10,000 Optimus robots for its operations.

Musk posted his clarification on social media platform X.

Alleged Optimus purchase

Recently, reports emerged stating that PharmAGRI Capital Partners will be tapping into Tesla’s humanoid robots for its operations. The firm claimed that it had executed a Letter of Intent with Tesla to deploy up to 10,000 Optimus Gen 3+ humanoid robots across its SuperPharm and CEA facilities. This should allow the company to automate its labor and ensure diversion control.

A comment from Lynn Stockwell, Chairwoman & CEO, suggested that the company really was partnering with Tesla. “With Tesla robotics powering our facilities and DEA-licensed infrastructure in place, we can scale with precision, meet federal sourcing mandates, and deliver therapies that are compliant, secure, and American-made,” she said. 

Elon Musk clariies

News of PharmAGRI’s Optimus claims quickly spread on social media, though some Tesla watchers argued that it seemed unlikely that the EV maker will commit two legions of Optimus robots to a rather unknown company this early. Some pointed out that Tesla typically commits to high-profile customers to test its early products, such as PepsiCo with the Tesla Semi. 

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Photos from PharmAGRI’s website depicting Tesla Optimus bots, as well as the rather basic look of the website itself, also brought more reservations to the company’s claims. Ultimately, Elon Musk weighed in on the matter, responding to a post about PharmAGRI’s Optimus-filled webpage. Musk was quick and direct, simply stating, “Fake.”

Elon Musk’s comments were quite unsurprising considering that Optimus is still very much in active development, and thus, it is quite unlikely that the company is already taking orders or even Letters of Intent from potential customers at this time. For now at least, Tesla seems determined to focus on the development of Optimus V3, which Musk has noted will be “sublime.”

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Elon Musk

Elon Musk: Self-sustaining city on Mars is plausible in 25-30 years

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization.”

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Credit: Elon Musk/X

Elon Musk has stated that a self-sustaining human settlement on Mars could be established in 25-30 years, provided launch capacity increases dramatically in the coming decades. 

Speaking at the All-In Summit, the SpaceX CEO said building a self-sufficient colony depends on exponential growth in “tonnage to Mars” with each launch window, highlighting Starship’s role as the company’s pathway to interplanetary initiatives.

Mars settlement goals

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization,” from food production to microchip manufacturing. Starship Version 3 is expected to support the first uncrewed Mars test flights, while future iterations could reach 466 feet in height and deliver larger payloads critical for settlement. Ultimately, Musk stated that an aggressive timeline for a city on Mars could be as short as 30 years, as noted in a Space.com report.

“I think it can be done in 30 years, provided there’s an exponential increase in the tonnage to Mars with each successive Mars transfer window, which is every two years. Every two years, the planets align and you can transfer to Mars. 

“I think in roughly 15, but maybe as few as 10, but 10-15-ish Mars transfer windows. If you’re seeing exponential increases in the tonnage to Mars with each Mars transfer window, then it should be possible to make Mars self-sustaining in about call it roughly 25 years,” Musk said. 

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Starship’s role

Starship has flown in a fully stacked configuration ten times, most recently in August when it completed its first payload deployment in orbit. The next flight will close out the Version 2 program before transitioning to Starship Version 3, featuring Raptor 3 engines and a redesigned structure capable of lifting over 100 tons to orbit.

While SpaceX has demonstrated Super Heavy booster reuse, Ship reusability remains in development. Musk noted that the heat shield is still the biggest technical hurdle, as no orbital vehicle has yet achieved rapid, full reuse.

“For full reusability of the Ship, there’s still a lot of work that remains on the heat shield. No one’s ever made a fully reusable orbital heat shield. The shuttle heat shield had to go through nine months of repair after every flight,” he said. 

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Tesla Model Y may gain an extra 90 miles of range with Panasonic’s next-gen battery

The Japanese company is pursuing an anode-free design.

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Credit: Tesla Manufacturing

Panasonic is developing a new high-capacity EV battery that could potentially extend the range of a Tesla Model Y by 90 miles. 

The Japanese company, one of Tesla’s key battery suppliers, is pursuing an anode-free design that it says could deliver a “world-leading” level of capacity by the end of 2027.

Panasonic’s anode-free design

The technology Panasonic is pursuing would eliminate the anode during the manufacturing process, as noted in a Reuters report. By freeing up space for more active cathode materials such as nickel, cobalt, and aluminum, the Japanese company expects a 25% increase in capacity without expanding battery size. 

That could allow Tesla’s Model Y to gain an estimated 145 kilometers (90 miles) of additional range if equipped with a battery that matches its current pack’s size. At the same time, Panasonic could use smaller, lighter batteries to achieve the Model Y’s current range. 

Panasonic also aims to reduce reliance on nickel, which remains one of the more costly raw materials. A senior executive previewed the initiative to reporters ahead of a scheduled presentation by Panasonic Energy’s technology chief, Shoichiro Watanabe.

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Tesla implications

The breakthrough, if achieved, could strengthen Panasonic’s position as Tesla’s longest-standing battery partner at a time when the automaker is preparing to enter an era of extreme scale driven by high-volume products like the Cybercab and Optimus.

Elon Musk has stated that products like Optimus would be manufactured at very high scale, so it would likely be an all-hands-on-deck situation for the company’s suppliers.

Panasonic did not share details on production costs or how quickly the new batteries might scale for commercial applications. That being said, the Japanese supplier has long been a partner of Tesla, so it makes sense for the company to also push for the next generation of battery innovation while the EV maker pursues even more lofty ambitions.

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