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SpaceX stacks first Super Heavy, creating largest rocket booster ever built

SpaceX has stacked its first Super Heavy booster, effectively completing the largest rocket booster ever assembled. (Elon Musk)

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For the first time ever, SpaceX has stacked a Super Heavy tank section to its full height, effectively completing assembly of the largest rocket booster ever built.

While a good amount of work still remains to weld the two halves together and connect their preinstalled plumbing and avionics runs, those tasks are largely marginal and will tweak the massive steel tower that’s now firmly in one piece. Comprised of 36 of the steel rings also used to assemble Starships, the first Super Heavy prototype – serial number BN1 – will stand roughly 67 meters (220 ft) tall from the top of its uppermost ring to the tail of its soon-to-be-installed Raptor engines.

At that height, Super Heavy BN1 is just 3 meters (~10 ft) shorter than an entire two-stage Falcon 9 or Falcon Heavy rocket – the second and third tallest operational rockets today. Of course, Super Heavy is just a booster and SpaceX says the rocket will stand at least 120m (~395 ft) tall with a Starship upper stage and spacecraft installed on top, easily making it the tallest (and likely heaviest) launch vehicle ever assembled.

Notably, Super Heavy BN1 isn’t fully representative of the boosters that will support Starship’s first orbital launch attempts. For unknown reasons, SpaceX appears to have forgone the installation of any kind of landing legs on the first pathfinder and prototype. CEO Elon Musk has expressed a desire to avoid the need for legs entirely by catching Super Heavy boosters (and possibly even Starships) with a tower outfitted with giant arms, but it’s virtually impossible to imagine that such a wholly unproven recovery mechanism will be ready for full-scale testing – let alone operational use – later this year.

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https://www.nasaspaceflight.com/2021/03/starship-sn11-spacex-orbital-flight-summer/
A Starship thrust dome sits to the left of Super Heavy BN1’s thrust dome. (NASASpaceflight – bocachicagal)

First reported by NASASpaceflight and later confirmed by Musk himself, SpaceX hopes to be ready to begin orbital Starship launches as early as July 2021, just four months from now. Per NASASpaceflight, that first launch attempt will nominally use Super Heavy booster BN3 and Starship SN20. Super Heavy BN1 is expected to remain grounded, serving as a testbed for inaugural pressure and proof tests, as well as one or several possible Raptor static fires (Update: confirmed by Musk).

If that process goes according to plan, Super Heavy BN2 will pick up where BN1 leaves off and attempt at least one short hop test, among other qualification tasks. In the interim between that feat and Super Heavy BN3’s launch preparations, it’s safe to assume that either BN2 or BN3 will support some kind of iterative static fire test campaign similar to what SpaceX once did with Falcon 9, gradually building up from tests with a half-dozen or so engines to static fires with 20 or more – possibly up to and including a full complement of 28 Raptors.

SpaceX installs BN1’s engine section on a custom workstand heavily reinforced for an entire Super Heavy booster. (NASASpaceflight – bocachicagal)

The first of its kind, booster BN1’s ‘thrust donut’ – a donut-shaped plate for the rocket’s center cluster of Raptor engines to attach to – appears to have been outfitted with hardware for four engines, suggesting a ceiling for static fire tests. It’s unclear when Super Heavy will roll to the launch pad for testing but it’s safe to say that SpaceX probably wont wait long after Starship SN11 is done with its high-altitude launch campaign. Stay tuned for updates!

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 and driver sued by family of woman killed in Texas crash: what we know

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Credit: CNBC

Tesla is being sued by the family of the woman who was killed in a Texas crash involving a Model 3. The driver, who is also being sued, claimed the vehicle was operating on Autopilot mode, but Tesla executives have come out challenging that claim, stating that the driver of the vehicle overrode the system.

The lawsuit was filed by 76-year-old Martha Avila’s daughter and her husband, who allege a “design defect” involving a Tesla and a failure to warn. The suit alleges negligence against Tesla and the driver, Michael Butler.

Butler “stated he was operating with an automated driving assistance system engaged at the time of the crash,” the Harris County Sheriff’s Office said in a statement. He showed no signs of intoxication and was cooperative, the Sheriff’s Office said, according to NBC News.

Just after reports of the crash and numerous headlines that immediately blamed Tesla’s Autopilot suite, both Tesla CEO Elon Musk and Head of AI Ashok Elluswamy challenged that. Musk said the crash made “no sense” given that Tesla Autopilot and Full Self-Driving do not travel at the speeds the door cameras captured the car traveling at, which Tesla says was 73 MPH.

Tesla finally clarifies fatal Texas crash, confirms driver manually overrode acceleration

Elluswamy also revealed that Tesla data showed Butler overrode the system by pressing the accelerator to 100%, and that the pedal was compressed fully even after the car had crashed. Tesla has not released this data to the public, likely because it is communicating with agencies like the NHTSA on an investigation.

The suit uses a Washington Post analysis of government data that “identified at least 17 fatal incidents linked to Tesla Autopilot.”

This is far from the first time an accident has been blamed on Autopilot. A fatal crash in Texas was blamed on Autopilot several years ago, but when Tesla released data to the NTSB, which was investigating the crash, Autopilot was not available where the crash occurred, and Autosteer was never enabled, meaning the car was manually controlled at the time of the accident.

More information on the accident will be released as Tesla works with agencies to find the cause of the crash. From personal experience, it is hard to imagine Tesla Autopilot or FSD operating in this manner. It drives sometimes too cautiously in residential areas in parking lots, at least in my experience. Speeding happens, but at this rate in this type of area, it is hard to believe.

We look forward to more details being released with time.

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Tesla Cybertruck is officially the safest pickup, IIHS says

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Credit: Tesla

The Insurance Institute for Highway Safety (IIHS) has awarded the 2025-2026 Tesla Cybertruck crew cab pickup its highest honor: Top Safety Pick+. This marks the Cybertruck as the only full-size pickup to achieve this distinction in recent evaluations.

The award applies specifically to vehicles built after April 2025, following structural upgrades including front underbody reinforcements and footwell modifications.

These changes enabled strong performance in updated crash tests. The Cybertruck earned “Good” ratings in the small overlap front (driver and passenger sides), updated moderate overlap front, and updated side tests—core requirements for the Top Safety Pick+ designation.

It also secured acceptable or good headlights across trims and a “Good” rating for its standard front crash prevention system in pedestrian scenarios, along with acceptable or good performance in vehicle-to-vehicle testing.

The Cybertruck avoided every single pedestrian collision, including:

  • Daytime child crossing
  • Nightitime adult crossing
  • Night parallel adult

In the large pickup category, competitors such as the Toyota Tundra received only a standard Top Safety Pick, while the Ford F-150 and Ram 1500 did not qualify for either award. This positions the Cybertruck as a standout in occupant protection and crash avoidance among its peers.

Credit: IIHS

Ironically, the same vehicle celebrated for superior U.S. safety performance remains banned from public roads in the United Kingdom and much of Europe. Regulators there cite the Cybertruck’s sharp external edges and highly rigid stainless-steel construction as failing pedestrian-protection standards. European and UK rules require rounded surfaces on protruding parts to minimize injury risk in collisions with vulnerable road users.

Critics also point to the truck’s substantial weight and unyielding body structure, which some argue could transfer more force to other vehicles or pedestrians rather than absorbing it.

Tesla’s engineering philosophy underpins the Cybertruck’s strong IIHS results. The vehicle features a distinctive stainless-steel exoskeleton made from ultra-hard 30X cold-rolled stainless steel. This provides exceptional structural rigidity and a robust safety cage that resists deformation in side impacts and rollovers.

Engineers designed integrated load paths to channel crash forces away from the occupant compartment while allowing controlled energy absorption in key zones. Post-April 2025 refinements to the front underbody further optimized performance in overlap crashes.

Complementing the passive structure is Tesla’s advanced active safety suite, including the standard Collision Avoidance Assist system with automatic emergency braking. This contributed directly to the vehicle’s strong front crash prevention scores. The skateboard platform and low center of gravity also enhance stability and handling, reducing the likelihood of certain crashes.

The IIHS recognition highlights how Tesla’s combination of high-strength materials, structural innovation, and software-driven safety systems can deliver top-tier protection in rigorous testing. While global regulatory differences on design and pedestrian interaction continue to limit the Cybertruck’s availability outside North America, its U.S. safety credentials set a new benchmark for full-size pickups.

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Elon Musk

SpaceX’s newest Starmind will make earth data centers obsolete

Elon Musk confirmed Starmind as SpaceX’s AI satellite constellation name, targeting one million orbital compute nodes.

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Elon Musk confirmed that Starmind will be the official name of SpaceX’s planned AI satellite constellation, following a trademark filing by xAI that surfaced earlier this week. Starmind is what’s being described to the FCC as a constellation of up to one million AI satellites

It’s worth noting that SpaceX’s Starlink communication satellite and Starmind are built on the same orbital infrastructure concept but serve entirely different purposes. Starlink is a connectivity network, with satellites receiving and relaying data between points on Earth, and functioning as a high-speed internet backbone in space. The satellites themselves do not process or think, and move information from one place to another, the same function a fiber cable performs underground.

SpaceX just forced Verizon, AT&T and T-Mobile to team up for the first time in history

Starmind, on the other hand, is something completely different, and tather than moving data, its satellites would compute data through artificial intelligence and directly in orbit using onboard processors powered by large solar arrays. Where a Starlink satellite is essentially a very fast pipe, a Starmind satellite is a server. The practical implication is that Starmind would allow AI models to run inference, process queries, and generate outputs from space, then beam results down to users anywhere on Earth within milliseconds, and without the data ever needing to travel to a terrestrial data center.

Starship will be able to carry 30 to 50 AI1 satellites per launch, delivering the equivalent of dozens of server racks per flight, with no land acquisition, no power grid approval, and no cooling infrastructure required on the ground.

SpaceX is pursuing this new technology as terrestrial data centers are running into hard limits such as lack of physical space, community opposition, and power and water consumption at a scale that is increasingly difficult to permit. Space has unlimited solar power, natural vacuum cooling, and no zoning boards. Musk said in a June 8 video presentation that he expects space to become the lowest-cost location to deploy AI compute within two to three years. Two AI1 prototypes are scheduled to launch in early 2027, with volume production targeted for the end of that year at a new facility called Gigasat.

The real world applications Starmind enables extend well beyond powering Grok. A constellation of orbiting AI processors could run inference workloads for any paying customer, anywhere on Earth, with latency measured in milliseconds rather than the seconds associated with ground-based cloud routing across continents. Starmind, if it scales as described, would make SpaceX the landlord of AI compute the same way Starlink made it the landlord of satellite internet.

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