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SpaceX fully stacks Starship rocket for the first time in six months

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For the first time in more than six months, SpaceX has stacked both stages of its next-generation Starship rocket, creating the largest and most powerful launch vehicle ever fully assembled.

It’s not the first time. SpaceX has conducted three other ‘full-stack’ Starship demonstrations: once in August 2021 and again in February and March 2022. But earlier this year, SpaceX (or at least CEO Elon Musk) decided to give up on the Starship upper stage and Super Heavy booster prototypes that had supported all three of those prior tests and, at one point, been considered a candidate for the rocket’s first orbital launch attempt. Booster 4 and Ship 20 were consigned to a retirement yard by June 2022.

By then, SpaceX had already begun testing the new favorites for Starship’s orbital launch debut: Super Heavy Booster 7 (B7) and Starship 24 (S24). Almost exactly six months after the start of that busy period of testing, both prototypes recently reached the point where SpaceX was confident enough in their progress to combine the two for the most challenging phase of Starship testing yet.

After an aborted predawn attempt on October 11th, SpaceX technicians worked out some mystery kinks in crucial infrastructure located at Starship’s first (nearly) finished orbital launch pad in Boca Chica, Texas. As part of a cart-before-horse gamble made by CEO Elon Musk that has seen SpaceX entirely remove legs from all recent Starship and Super Heavy prototypes in the hope that it will one day be able to catch the building-sized rocket stages out of mid-air, the company has built a launch tower ~145 meters (~475 ft) tall and outfitted it with three giant robotic arms. Two of those arms are identical and linked together, forming a sort of claw that could one day close around hovering rockets to preclude the need for landing legs. A simpler third arm swings in and out to connect Starship’s upper stage to the launch pad’s power, propellant, and gas supplies.

The ‘chopsticks,’ as they’re known, have another even more important purpose: assembling Starship rockets at the launch pad. Thanks to their sturdy connection to a tower with a foundation sunk deep into the Boca Chica wetlands and a design that forgoes a hanging hook or jig for giant arms, they are far less sensitive to winds than the immense crane otherwise required to stack Starship on top of Super Heavy. Sitting a stone’s throw from the Gulf of Mexico, storms and high winds are not exactly uncommon.

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Around sunset on October 11th, SpaceX had better luck on its third attempt and was able to move the arms into place under Ship 24. Weighing 100 tons or more (~220,000+ lb) and measuring nine meters (~30 ft) wide and ~50 meters (~165 ft) tall, the Starship was then slowly lifted about 80 meters (~250 ft) off the ground, translated over to Booster 7, and lowered on top of the 69-meter-tall (~225 ft) first stage. After about two more hours of robotically tweaking their positions, the two Starship stages were finally secured together. With the arms still attached to Ship 24, SpaceX workers were able to approach the rocket and prepare to connect the swing arm’s quick-disconnect umbilical to Starship.

Ship 24 and Booster 7 have both completed several major tests to date. (SpaceX)

Since they began qualification testing in April and May 2022, Booster 7 and Ship 24 have each completed several cryogenic proof tests, eight ‘spin-primes’ of some or all of their Raptor engines, and several static fires of those same engines. Most recently, Ship 24 ignited all six of its Raptors, but the seemingly successful September 8th test was followed by more than a month of apparent repairs. Booster 7 last completed a static fire that ignited a record seven of its 33 Raptor engines – offering an idea of how much further SpaceX still has to go to finish testing the Super Heavy.

According to CEO Elon Musk, Booster 7 and Ship 24 will attempt Starship’s first full-stack wet dress rehearsal (WDR) once all is in order. The prototypes will be simultaneously loaded with around 5000 tons (~11M lb) of liquid oxygen and methane propellant and then run through a launch countdown. Diverging just before ignition and liftoff, a WDR is meant to be more or less identical to a launch attempt.

If the wet dress rehearsal goes to plan, SpaceX will then attempt to simultaneously ignite all 33 of the Raptor engines installed on Super Heavy B7, almost certainly making it the most powerful liquid rocket ever tested. Even if all 33 engines never reach more than 60% of their maximum thrust of 230 tons (~510,000 lbf), they will likely break the Soviet N-1 rocket’s record of 4500 tons of thrust (~10M lbf) at sea level. It would also be the most rocket engines ever simultaneously ignited on one vehicle. SpaceX will be pushing the envelope by several measures, and success is far from guaranteed.

It’s unclear if SpaceX will immediately attempt a full wet dress rehearsal or 33-engine static fire. Based on the history of Ship 24 and Booster 7 testing, it would be a departure from the norm if the company doesn’t slowly build up to both major milestones with smaller tests in the interim. At minimum, assuming WDR testing is completed without major issue, SpaceX will likely attempt at least one or more interim static fires with fewer than 33 engines before attempting the first full test.

If both milestones (a full WDR and 33-engine static fire) are completed without significant issue, there’s a chance that SpaceX could move directly into preparations for Starship’s first orbital launch attempt without unstacking the rocket. In the likelier scenario that some issues arise and some repairs are required, the path will be more circuitous but should still end in an orbital launch attempt late this year or early next.

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Booster 7’s 33 Raptor V2 engines. (SpaceX)
Mechazilla’s third successful Starship stack. (SpaceX)

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 leads South Korea’s EV growth in 2025

Data from the Korea Automobile and Mobility Industry Association showed that the Tesla Model Y emerged as one of the segment’s single biggest growth drivers.

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Credit: Tesla Malaysia/X

South Korea’s electric vehicle market saw a notable rise in 2025, with registrations rising more than 50% and EV penetration surpassing 10% for the first time. 

Data from the Korea Automobile and Mobility Industry Association showed that the Tesla Model Y, which is imported from Gigafactory Shanghai, emerged as one of the segment’s single biggest growth drivers, as noted in a report from IT Home News.

As per the Korea Automobile and Mobility Industry Association’s (KAMA) 2025 Korea Domestic Electric Vehicle Market Settlement report, South Korea registered 220,177 new electric vehicles in 2025, a 50.1% year-over-year increase. EV penetration also reached 13.1% in the country, entering double digits for the first time. 

The Tesla Model Y played a central role in the market’s growth. The Model Y alone sold 50,397 units during the year, capturing 26.6% of South Korea’s pure electric passenger vehicle market. Sales of the Giga Shanghai-built Model Y increased 169.2% compared with 2024, driven largely by strong demand for the all-electric crossover’s revamped version.

Manufacturer performance reflected a tightly contested market. Kia led with 60,609 EV sales, followed closely by Tesla at 59,893 units and Hyundai at 55,461 units. Together, the three brands accounted for nearly 80% of the country’s total EV sales, forming what KAMA described as a three-way competitive market.

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Imported EVs gained ground in South Korea in 2025, reaching a market share of 42.8%, while the share of domestically produced EVs declined from 75% in 2022 to 57.2% last year. Sales of China-made EVs more than doubled year over year to 74,728 units, supported in no small part by Tesla and its Model Y.

Elon Musk, for his part, has praised South Korean customers and their embrace of the electric vehicler maker. In a reply on X to a user who noted that South Koreans are fond of FSD, Musk stated that, “Koreans are often a step ahead in appreciating new technology.”

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Samsung’s Tesla AI5/AI6 chip factory to start key equipment tests in March: report

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant.

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Image used with permission for Teslarati. (Credit: Tom Cross)

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant, which will produce Tesla’s next-generation AI5 chip. 

Preparing for Tesla’s AI5/AI6 chips

As per a report by Sina Finance, Samsung Electronics is looking to begin trial operations of extreme ultraviolet (EUV) lithography equipment at its Taylor facility in March. These efforts are reportedly intended to support the full production of Tesla’s AI5 chips starting in the latter half of 2026.

The Taylor factory, Samsung’s first wafer fabrication plant in the United States, covers roughly 4.85 million square meters and is nearing completion. Media reports, citing contractors, have estimated that about 7,000 workers now work on the factory, about 1,000 of whom are reportedly working from the facility’s office building. 

Samsung is reportedly preparing to apply for a temporary occupancy permit, which would allow production to begin before the plant is fully completed.

Tesla’s aggressive AI chip roadmap

Elon Musk recently stated that Tesla’s next-generation AI5 chip is nearly complete, while early development on its successor, AI6, is already underway. Musk shared the update in a post on X, which also happened to be a recruiting message for engineers.

As per Musk, Tesla is looking to iterate its in-house AI chips on an accelerated timeline, with future generations, including AI7, AI8, and AI9, targeting a roughly nine-month design cycle. He also stated that the rapid cadence could allow Tesla’s chips to become the highest-volume AI processors in the world.

Previous reports have indicated that Samsung Electronics would be manufacturing Tesla’s AI5 chip, alongside its rival, Taiwan Semiconductor Manufacturing Company (TSMC). The two suppliers are expected to produce different versions of Tesla’s AI5 chip, with TSMC using a 3nm process and Samsung targeting 2nm production.

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Elon Musk’s Boring Company studying potential Giga Nevada tunnel: report

The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

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the-boring-company-tesla-robotaxi
(Credit: The Boring Company

Elon Musk’s tunneling startup, The Boring Company, has been studying a potential tunnel system connecting Reno to Tesla Gigafactory Nevada, as per documents obtained by Fortune. The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

Potential Giga Nevada tunnel

Documents reviewed by Fortune showed that The Boring Company received $50,000 in October to produce conceptual designs and a feasibility report for a tunnel beneath a nine-mile stretch of highway leading to Gigafactory Nevada. The payment came from the Economic Development Authority of Western Nevada (EDAWN), a nonprofit that works with the state to attract and expand businesses.

The proposed tunnel was one of several transportation alternatives being explored to address rising congestion and accidents along Interstate 80, which serves the Tahoe-Reno Industrial Center. The massive industrial park houses major employers, including Tesla and Panasonic, both of which had been in contact with the Nevada Governor’s Office regarding potential transportation solutions.

Emails obtained through public records requests showed that Tesla and Panasonic have also supported a separate commuter rail study that would use existing freight rail alongside the Interstate. It remains unclear if The Boring Company’s feasibility report had been completed, and key details for the potential project, including tunnel length, cost, and if autonomous Teslas would be used, were not disclosed.

The-boring-company-vegas-loop-chinatown
(Credit: The Boring Company)

Relieving I-80 congestion

Traffic and accidents along I-80 have increased sharply as data centers and new businesses moved into the 107,000-acre industrial center. State transportation data showed that the number of vehicles traveling certain stretches of the highway during peak hours doubled between January and July 2025 alone. Roughly 22,000 employees commute daily to the industrial park, with nearly 8,000 working for Tesla and more than 4,000 for Panasonic at the Giga Nevada complex.

Bill Thomas, who runs the Regional Transportation Commission of Washoe County, shared his thoughts about safety concerns in the area. “At this point in time, there’s about (one accident) every other day,” he said. He also noted that he is supportive of any projects that could alleviate traffic and accidents on the Interstate. 

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“We’re not paying for it. I’m not involved in it. But I understand there are conversations exploring whether that could be done. If there’s a private solution that helps the problem and improves safety, as far as I’m concerned, more power to them,” Thomas stated. 

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