News
SpaceX fully stacks Starship rocket for the first time in six months
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.
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.
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.
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Lifestyle
Tesla app update makes Robotaxi ownership make a lot more sense
Tesla’s app now shows a live indicator when your car is actively driving itself.
A recent Tesla app update, released last week (4.58.5), gives visibility on whether a vehicle is navigating in its semi-autonomous mode or being drive by a human driver. The updated app now displays a live “Self-Driving” indicator in bright blue text directly beneath the vehicle’s speed readout whenever Full Self-Driving is actively engaged, along with the signature glowing blue navigation path that FSD users see on the main touchscreen. It is a small visual update with meaningful implications for how Tesla owners monitor their vehicles remotely.
The feature was first spotted in the wild by X user Jordan Camina, who shared video of a Hardware 3 Model S displaying the new animation through the app while driving. That detail is significant because it confirms the update is not limited to newer HW4 vehicles. It works across hardware generations, and Tesla confirmed it will eventually support all vehicles regardless of chip platform once both the app and vehicle software are updated. The vehicle side requires software version 2026.20.6.1, which has reached nearly 40% of the fleet so far, as monitored by NotaTeslaApp.
The feature makes the most practical sense when viewed through the lens of Tesla’s expanding robotaxi operation. In a robotaxi context, the owner of a vehicle generating ride revenue has a direct financial and safety interest in knowing whether their car is operating under autonomous control at any given moment. The app’s new FSD indicator gives fleet owners exactly that visibility, the same way a logistics company monitors whether a delivery driver is following the planned route. It also carries implications for Tesla’s insurance model. Tesla’s own insurance product prices premiums in part based on FSD engagement rates, and real-time visibility into when FSD is active creates a feedback loop that could eventually tie directly into policy pricing. For individual owners who have opted their personal vehicles into the robotaxi network, the update effectively turns the Tesla app into a fleet management dashboard, one that tells you whether your car is earning money, whether it is driving itself to do it, and whether everything is operating the way it should from wherever you happen to be.
Tesla expands Robotaxi to Florida, marking its third state for autonomy
As Teslarati has reported, Tesla launched unsupervised robotaxi rides in Miami this summer, a milestone that makes a remote FSD status indicator significantly more practical than a cosmetic feature. When a vehicle is operating as a robotaxi without a driver present, the owner or fleet operator needs a reliable way to confirm autonomy is engaged. The app now provides exactly that.
As noted by NotATeslaApp, The update also arrived alongside a hint buried in the same app version that Tesla plans to use the cabin camera to verify driver identity before FSD can be activated. Pairing identity verification with a live autonomy status indicator points toward the infrastructure Tesla is building for a fleet of driverless vehicles that owners can monitor the way you would track a package delivery.
Tesla battery recycling efforts increased 20 percent last year
Tesla FSD is about to know your specific house and neighborhood better than any map
