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SpaceX’s first two Super Heavy boosters making good progress towards test debuts

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SpaceX is making good progress on Starship’s first two Super Heavy boosters, both of which could potentially be ready for their first major test campaigns before the end of the year.

On November 19th, some ten weeks after the process began, SpaceX craned Super Heavy B5’s methane (LCH4) tank on top of its oxygen (LOx) tank, marking the end of major structural assembly for the 69m (~225′) tall booster. A team of welders has since been working around the clock to weld the two tanks together and complete a transfer tube that routes methane propellant down through B5’s oxygen tank.

Two days prior, CEO Elon Musk shared a photo of SpaceX’s other Super Heavy booster (B4) which has been slowly progressing towards test readiness for more than three months. It’s unclear why SpaceX has been so sluggish to prepare Super Heavy B4 for testing but with B5 finally approaching the finish line, the company will soon find itself in a position where it will need to decide which booster to proceed with towards the program’s near-term end goal: the first orbital Starship test flight.

Once Booster 5’s two halves are welded together, only a few things will set it and Booster 4 apart. In recent weeks, SpaceX’s slow progress on Super Heavy B4 relented a bit as technicians began closing out the booster’s raceway (a conduit for plumbing, wiring, and avionics) with basic covers. More importantly, SpaceX also began reinstalling Raptor engines and installing heat shielding around those engines for the first time. In the photo Musk published on November 17th, that heat shield is easily visible and there are signs that it will ultimately enclose the entire outer ring of 20 Raptor Boost engines above their nozzles.

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Once complete, that shield will theoretically protect each engine’s nest of sensitive plumbing and wiring during static fires; ascent, boostback, and landing burns; and – most importantly – reentry. Unlike Falcon boosters, which always perform a ~30-second, three-engine ‘reentry burn’ to slow down and cushion the blow of reentry heating, SpaceX plans to recover steel Super Heavy boosters without reentry burns. In theory, that should making booster recovery more efficient, allowing another dozen or so tons of propellant to go towards sending Starship to orbit instead of landing.

Super Heavy B4 before and after the start of Raptor heat shield installation. (SpaceX)

As of November 17th, SpaceX has reinstalled all 29 Raptor engines on Booster 4, partially finished the outer ring of Raptor heat shields, and set the stage for more heat shielding around its 9 center engines and the gap between those inner and outer Raptors. Shielding the Raptor Center engines in a way that still seals off Super Heavy’s aft will be even more challenging given that all nine need to be able to freely gimbal to vector their thrust, while the outer ring of 20 Raptor Boost (RB) engines are fixed in place. At pace of work established over the last few months, it will likely take SpaceX several more weeks to finish that heat shield and install seven ‘aerocovers’ over racks of sensitive equipment installed around Booster 4’s base.

Booster 4, September 8th. (SPadre)

Super Heavy Booster 5, on the other hand, has taken a slightly different path through assembly. Unlike Booster 4, which first rolled out as little more than a giant steel tank with Raptors half-installed, SpaceX appears to have installed most of Booster 5’s external plumbing, wiring, equipment racks, and maybe even the start of its Raptor heat shield during assembly instead of after. Perhaps as a result, SpaceX has taken more than ten weeks to stack Booster 5 versus 2.5 weeks for Booster 4. But given that Booster 4 still doesn’t appear to be complete some 18 weeks after its assembly began, there’s a chance that Booster 5 will ultimately take 4-6 weeks less to reach initial test readiness.

If SpaceX does complete Super Heavy B5 well ahead of B4’s schedule, it will soon find itself with two test-ready Starship boosters but only one orbital-class stand with which to test them, potentially forcing the company to make some interesting decisions.

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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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