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SpaceX rolls out first new Starship prototype in nine months
For the first time in more than nine months, SpaceX has rolled a new Starship prototype to its Starbase, Texas launch facilities in the hopes of kicking off qualification testing in the near future.
The new activity exemplifies just how different – and more subdued – Starbase’s last year has been compared to the year prior. However, it also signals new hope for a significantly more eventful 2022 as SpaceX once again finds itself preparing for Starship’s first orbital launch attempt – albeit with an entirely different rocket.
The last time SpaceX rolled a new and functional Starship prototype from the factory to the test stand was on August 13th, 2021, when Starship S20 was transported back to the pad for the second time that month. On August 5th, the same unfinished Starship was stacked on top of Super Heavy booster B4, briefly assembling the largest rocket ever built. With the luxury of hindsight, it’s now clear that that particular milestone was more of a photo-op than a technical achievement. Nonetheless, Ship 20’s path was far more productive than Booster 4’s. The Starship returned to the Starbase factory for a few days of finishing touches before arriving back at the pad on August 13th. Only in the last week of September did Ship 20 finally begin its first significant tests, followed by its first Raptor static fire in mid-October. In mid-November, Ship 20 completed the first of several successful six-Raptor static fires.
Ultimately, by the time Ship 20 was retired in May 2022, the Starship was arguably fully ready to attempt to reach orbit or at least perform some kind of ambitious hypersonic test flight. However, Super Heavy Booster 4 never made it even a fraction of the way to a similar level of flight readiness and SpaceX never received the FAA environmental approval or launch license needed for an orbital launch attempt.
Only now, in May 2022, does it finally look likely that SpaceX will finally receive the necessary permissions for a limited orbital test flight campaign in the near future. While it’s hard to say if Booster 4 and Ship 20 could have supported some kind of launch campaign if permission had been granted months ago, what’s clear is that all aspects – flight hardware, pad hardware, and bureaucracy – have been chronically delayed to the point that Booster 4 and Ship 20 are now heavily outdated.
In their place, now, stand Super Heavy B7 and Starship S24 – the new ‘chosen ones’ assigned to Starship’s orbital launch debut. Both feature extensive design changes and account for an upgraded version of the Raptor engine and countless lessons learned over the better part of a year spent troubleshooting and testing their predecessors. While it did get off to a rocky start, Booster 7 has already completed several cryogenic proof tests and is in the middle of being outfitted with 33 new Raptor engines.
On the other hand, perhaps indicating SpaceX’s satisfaction with Ship 20’s performance, Starship S24 has been on the back burner in comparison. Only on May 26th, 2022 did SpaceX finally finish the prototype to the point that it was ready to begin qualification testing. Missing hundreds of TPS tiles and an aerocover cap, Ship 24 was quickly moved into position at a sort of drive-by test stand where it appears the prototype will first need to pass basic pressure and cryogenic proof tests.
If it passes those tests, SpaceX will then install Ship 24 on a suborbital launch and test stand (Suborbital Pad A) that has been significantly modified for qualification testing. Rather than leaping straight into static fires, SpaceX will minimize the risk of catastrophic failure by first using hydraulic rams to simulate the thrust of six Raptor V2 engines while Starship’s steel tanks and plumbing are chilled to cryogenic temperatures. Only after Ship 24 completes stress testing will SpaceX install new Raptor engines and prepare to replicate Ship 20’s success with several static fires.
Thanks to Raptor V2’s improvements, Ship 24 will likely need to withstand around 1400 tons (~3.1M lbf) of thrust at liftoff – almost 25% more than Ship 20 ever experienced. Beyond a sturdier thrust section, Ship 24 is also the first Starship SpaceX has outfitted with a next-generation nose; the first with a significant landing propellant (‘header’) tank redesign; and the first with a potentially functional payload bay and door.
Assuming Ship 24 passes all planned cryoproof and thrust simulation tests, it remains to be seen if SpaceX will return the Starship to Starbase factory facilities or – like with Ship 20 – install Raptors and finish its heat shield and thermal protection while sitting on the test stand. SpaceX has two test windows currently scheduled: one from 6am to 12pm CDT on Friday, May 27th and the other from 10am to 10pm CDT on Tuesday, May 31st.
Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
Tesla is expanding its Robotaxi service hours by pushing the time back by one hour, keeping the ride-hailing service operational until 11 p.m., one hour later than previously.
CEO Elon Musk confirmed the change and offered a specific reason the expansion has been gradual: the system still needs to reliably avoid small pets that are difficult to see after dark, as they commonly blend into the color of the road, especially when they’re grey.
The latest adjustment restores only a fraction of the operating window the service once held. When paid Robotaxi rides began in Austin on June 22, 2025, vehicles ran from 6 a.m. to midnight.
In September 2025, Tesla lengthened the day to a 2 a.m. close, producing a 20-hour window that stayed in place for most of the following year. By early August of this year, the cutoff had already been pulled back; an August 26 update formalized hours of 6 a.m. to 10 p.m. across Austin and several other markets.
The October move to 11 p.m. therefore leaves the Austin day one hour shorter than the original launch schedule and three hours shorter than the 2025 peak.
Musk addressed the constraint directly after the announcement. “The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night,” he wrote. “Literally trying to avoid grey kittens on grey tarmac in the dark.”
Robotaxi operating hours moved from 10pm to 11pm.
The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night. Literally trying to avoid grey kittens on grey tarmac in the dark.
— Elon Musk (@elonmusk) October 3, 2026
The example points to a low-contrast perception problem in which a small animal can blend into the road surface under limited lighting.
Tesla’s vehicles rely on cameras and neural-network processing rather than lidar; Musk has previously argued that advanced vision software can extract useful information even in low light by analyzing photon counts, but the pet-detection case remains the stated limiter in later hours.
The modest schedule change arrives alongside faster growth in the purpose-built Cybercab fleet. Texas registration data tracked by observers showed the Austin Cybercab count rising sharply in recent weeks, reaching 169 vehicles after more than 100 were added in a short span.
Tesla has indicated that a broader shift toward 24-hour operation is tied to the upcoming FSD v15 software release expected this month on Robotaxi vehicles. Until that capability is validated for the edge cases Musk described, the company continues to add service time incrementally rather than jumping straight to overnight coverage.
The one-hour extension gives Austin riders a later option for evening trips while the underlying detection work continues.
Elon Musk teases TSMC as potential Terafab partner
Tesla reveals early Robotaxi charging strategy, showing scrappy DNA
