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SpaceX installs rocket-catching arms on Starship’s Florida launch tower

SpaceX has installed a pair of giant arms at Starship's first Florida launch site. (Twitter - @McOfficialPlays)

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SpaceX has installed a pair of rocket-catching arms on a tower meant to support the first East Coast launches of its next-generation Starship rocket.

The company has been building the second of several planned Starship launch sites for more than three years. Ironically, work on that pad began before the company started building the pad that will actually support Starship’s first orbital launch attempts. Located a stone’s throw from the Gulf of Mexico in Boca Chica, Texas, the first iteration of SpaceX’s Starbase orbital launch site (OLS) is nearly complete and could host Starship’s orbital launch debut in a matter of months. SpaceX began constructing Starship’s Texas launch site in earnest in late 2020.

SpaceX broke ground on Starship’s first Florida OLS in late 2019. But the company went on to radically redesign the rocket and its ground systems, forcing it to entirely abandon about a year of work by the end of 2020. In late 2021, SpaceX finally began constructing the second iteration of Starship’s first Florida pad. OLS #2 is still colocated at Kennedy Space Center’s LC-39A pad, which SpaceX leases from NASA. Pad 39A is the only site currently capable of launching SpaceX’s Crew Dragon astronaut spacecraft or Falcon Heavy rocket, which has complicated its plans to use the same pad for Starship.

Because of NASA’s trepidation at the thought of a Starship failure indefinitely delaying SpaceX from completing its Crew Dragon or Falcon Heavy contracts for the agency, the company deprioritized Starship’s Florida pad, slowing progress. SpaceX has, nonetheless, made significant progress. In 13 months, SpaceX has created foundations, modified one of Pad 39A’s giant spherical tanks to store cryogenic methane, installed miles of plumbing, built and assembled a second skyscraper-sized Starship launch tower, installed the legs of the pad’s ‘orbital launch mount’ or OLM, installed a water deluge system at the base of the OLM, assembled most of the OLM’s donut-like mount offsite, constructed a new supersized storage tank, and delivered a forest of smaller storage tanks.

Most recently, SpaceX finished building a giant pair of steel arms, transported the arms to Pad 39A, attached them to a wheeled carriage, and installed the structure on Starship’s Florida launch tower. SpaceX employees have nicknamed the arms “chopsticks,” and those arms are integral to what CEO Elon Musk calls “Mechazilla”. Mechazilla refers to the combined launch tower and arms, which SpaceX has designed to grab, lift, stack, and fuel both stages of Starship.

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Mechazilla’s simplest part is a third arm that is vertically fixed in place but capable of swinging left and right. The swing arm contains plumbing and an umbilical device that connects to Starship’s upper stage and supplies propellant, gas, power, and connectivity. The tower’s ‘chopsticks’ are far more complex. Giant hinges connect the pair of arms to a carriage that grabs onto three of the tower’s four legs with a dozen skate-like appendages. Those skates are outfitted with wheels, allowing the carriage to roll up and down tracks built into the tower’s legs.

SpaceX stress-tests the first ‘chopsticks’ with water bags. (NASASpaceflight – bocachicagal)
The first “Mechazilla” lifts Starship 24 onto Super Heavy Booster 7. (SpaceX)
At the bottom, the swing arm connects to Starship to supply propellant. The catch arms are used to stabilize the rocket before and after testing. (SpaceX)

The carriage, which also carries the complex hydraulic systems that allow its bus-sized arms to move, is connected by steel cable to a heavy-duty “draw works” capable of hoisting the multi-hundred-ton assembly up and down the tower. Once finished, the Florida tower’s arms will be able to precisely lift, maneuver, stack, and de-stack Starship and Super Heavy even in relatively windy conditions. At some point in the future, SpaceX may attempt to use its towers and chopsticks to catch Starships and Super Heavies out of mid-air and speed up reuse.

Set to be the largest, most powerful, and most capable rocket in history, Starship is primarily built out of steel and designed to be fully reusable. SpaceX has a long way to go to demonstrate that the 120-meter-tall (~390 ft) rocket can reach orbit, let alone be reused. In theory, though, Starship is meant to launch up to 150 metric tons (330,000 lb) to low Earth orbit (LEO) while still allowing for the recovery and reuse of its suborbital Super Heavy booster and orbital Starship upper stage.

If SpaceX can achieve those figures, Starship will be the most capable rocket in history even with the major performance penalties that full reusability entails. Saturn V, the most capable rocket ever flown, was fully expendable and could launch up to 118 metric tons (~260,000 lb) into orbit.

Due to NASA’s concerns about the risks that Starship launches from Pad 39A could pose to SpaceX’s Falcon and Dragon operations at the same site, the company’s next-generation rocket may have to wait until 2024 or 2025 for its first Florida launch. With the first Florida Mechazilla now close to completion, it’s likely that Pad 39A’s Starship launch site will be ready and waiting as soon as NASA gives SpaceX the green light.

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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’s Elon Musk gives nod to Ford while acknowledging his influence on EVs

“Ford basically invented mass manufacturing of large, complex products. Everyone else copied.”

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Credit: Tesla, Ford

Tesla CEO Elon Musk gave a tremendous nod to Ford while also acknowledging his own influence on EVs and the automotive industry in general.

Yesterday, Ford announced its new manufacturing process for EVs, which was essentially a rebirth of its own production lines and plans for more affordable models to offer consumers.

It was important to recognize that Ford truly launched automotive manufacturing with its production of the Model T 122 years ago.

That’s exactly what Musk did in a response to Ford CEO Jim Farley:

In the over 100 years since Ford started producing vehicles, the company has had one significant fact go under the radar: it truly created a great process for building large, complex vehicles. It is something that many companies eventually adopted as the car industry took off.

Tesla is in a similar situation. It has used things like the Giga Press from the Italian company IDRA to create a better, more efficient, streamlined process for building cars.

It was able to use casting to eliminate a vast majority of parts from the Model Y, which not only helped increase manufacturing efficiency but also improved safety and structural rigidity. It truly revolutionized manufacturing for the company, and Ford said that it would adopt a similar mindset with its new EVs.

Yesterday, Doug Field, the Chief EV, Digital and Design Officer for Ford, and a former Sr. VP of Engineering for Tesla, said the company was taking the mentality that “the best part is no part.”

Musk acknowledged how far it has come and how it is influencing other car companies to do the same in terms of its production strategy:

Ford is using an “Assembly Tree,” which is essentially very similar to Tesla’s “unboxed production process.” In addition to the use of Gigacasting, which Ford is calling “Unicasting,” as well as the use of structural batteries, it is almost as if Tesla is having its own “Model T moment.”

Ford has been quick to adopt an EV mentality as it plans to transition its business over the next decades. It is working to prepare for the future of the atuomotive industry, and although it has adjusted its strategy, it can’t be denied that Ford is one of the legacy automakers taking this new chapter in cars seriously.

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Tesla has one big bottleneck with its public Robotaxi launch, but it can fix it easily

Elon Musk plans for Tesla Robotaxi to be open to the public in Austin in September.

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Credit: Dave Lee

Tesla CEO Elon Musk said that the company’s Robotaxi program would open to the public in September, but there is one big bottleneck that would inhibit it from launching smoothly.

The thing is, it can be resolved in no time, and Tesla can fix it internally.

In Austin, the Robotaxi platform has been in operation since late June. The launch of the program only allowed a handful of privileged influencers and groups to access the driverless ride-hailing service, although it has expanded this group on several occasions.

It has also slowly added vehicles to the fleet, starting at 11 cars when it launched in June. There have been a few cars added, but Tesla has continued to prioritize safety, keeping its rider population and number of vehicles low for the time being.

However, this is going to cause quite a bit of a bottleneck in next month’s planned public launch, as there will be an open invitation for anyone and everyone to test out the Robotaxi platform in Austin.

Tesla CEO Elon Musk confirms Robotaxi is opening to the public: here’s when

Many people have been waiting for an invitation to ride in a Robotaxi, and Tesla has not been prone to give one to just anybody.

As that becomes a much larger number next month, Tesla is going to have to step up its Robotaxi fleet number, as well as its population of Safety Monitors, the riders that sit in the passenger seat to ensure everything goes smoothly.

While the geofence in Austin has roughly doubled in size twice during both of Tesla’s expansions of the service area, the company is still playing it safe with rider population growth, something that aligns with its focus on safety.

Musk said recently about the expansion of Robotaxi to customer-owned vehicles:

“As I said, we’re being paranoid about safety. But I guess next year is I’d say confidently next year. I’m not sure when next year, but confidently next year, people would be able to add or subtract their car to the Tesla, Inc. fleet.”

The Robotaxi fleet will, without a doubt, revolutionize the way people view ride-hailing. Tesla seems ready to open it up to the public next month, based on what Musk said, but some changes will have to occur to ensure it goes smoothly.

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Tesla Model Y L spotted in Europe ahead of expected September China launch

Tesla’s long-wheelbase Model Y L has seemingly been spotted in Europe.

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Credit: Tesla

Tesla’s long-wheelbase Model Y L has seemingly been spotted in Europe, signaling its upcoming debut outside China. A lightly camouflaged prototype was seen at a charging station near Germany’s Nürburgring, hinting that the extended wheelbase crossover will make its way to European markets after its expected September launch in China.

The Model Y L

The Model Y L, which will be offered in a six-seat configuration, is expected to add roughly 178 mm (7 inches) to the overall length of the standard Model Y, with 152 mm (6 inches) dedicated to stretching the wheelbase, as noted in an autoevolution report. This design tweak should unlock more third-row space, and it should be enough to rival the rear seating comfort of the much more expensive Model X, which can no longer be ordered in Europe.

While initially mistaken for a Model Y Performance during testing, the prototype’s extended rear door cutout and 19-inch wheels, which were unusual for a Performance variant, suggested that the covered unit was actually the Model Y L. The prototype’s wheels, if any, match those listed in China’s Ministry of Industry and Information Technology (MIIT) filing for the upcoming Model Y L.

Model Y L production

Tesla is expected to build the Model Y L at Giga Shanghai for the Chinese market initially, though speculations are high that the vehicle will also be built at Giga Berlin in Germany, as well as the Fremont Factory and Giga Texas in the United States. Recent reports have suggested that the Model Y L’s production in China has already begun, and sales there are slated to start in September. 

Considering the Model Y L’s lower entry price compared to the flagship Model X, the upcoming extended wheelbase crossover could quickly become Tesla’s new premier SUV for families needing extra passenger capacity, at least without stepping into the premium pricing bracket of the Model X.

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