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SpaceX shrugs off Starship implosion and gets back to work as Elon Musk talks next steps

Technicians have already begun stacking and integrating different sections of Starship SN02. (NASASpaceflight - bocachicagal)

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SpaceX has shrugged off the catastrophic implosion of its first serial Starship prototype (SN01) and begun stacking sections of the next ship (SN02) while CEO Elon Musk talks next steps for the next-generation rocket program.

By now, it’s reasonably clear that the demise of Starship SN01’s tank and engine section came as a bit of surprise to SpaceX itself, while it assuredly shocked non-employees and local residents who happened to be watching on eve of the anomaly. CEO Elon Musk himself appears to have expected different results, noting that – thankfully – the likely source of the Starship’s unforeseen failure had already been determined.

Despite the apparent setback, it appears that SpaceX won’t have to wait long at all to continue its uniquely ‘hardware-rich’ Starship test campaign. With a workforce now several hundred strong and a great deal of hands-on and strategic experience gained from building Starships Mk1 and SN01, SpaceX is now practically churning out parts for future Starship SNxx prototypes. Most notably, Starship SN01’s predecessor is potentially just a few days away from being stacked into a finished tank section, hinting at the almost unfathomably speed that SpaceX is able to build full-scale vehicles even in early days of the program.

Three days after Starship SN01’s spectacular implosion and unintentional ‘launch’, SpaceX CEO Elon Musk took to Twitter to share a video captured by local Boca Chica Village resident ‘bocachicagal’ and posted by NASASpaceflight.com. Attached above, Mary’s video offers an incredibly vivid view of the rocket’s violent demise while further revealing the apparent location where the failure started – Starship SN01’s engine section and thrust structure.

Given that Musk already revealed that Starship SN02 would feature improved tank welds, it’s safe to assume that the prototype will also have an improved thrust structure (i.e. “puck”).

Confirming suspicions, Musk quickly implied that the Starship’s failure originated in or around its thrust structure (‘thrust puck’), further noting that Starship SN02 – already in the middle of production – would be “stripp[ed]…to [the] bare minimum to test the thrust puck to dome weld.” In essence, it sounds like Starship SN02 will become SpaceX’s third intentional “test tank”, following in the footsteps of two small Starship tanks built and pressurized to failure to verify the quality of Starship manufacturing.

Starship SN01’s ‘thrust puck’ or thrust structure and aft liquid oxygen tank dome are pictured on February 12th. (NASASpaceflight – bocachicagal)
Starship SN02’s ‘thrust puck’ – pictured on March 2nd – already looks substantially different. (NASASpaceflight – bocachicagal)

Starship SN02’s thrust structure design already appears to be a departure from SN01’s apparently unsuccessful iteration. Given that it was already partially completed before Starship SN01 failed during testing, it’s possible that SpaceX will attempt to reinforce the SN02 thrust structure, but the company may have already implemented upgrades before its engineers had the benefit of hindsight from February 28th’s test.

Regardless of what happens to Starship SN02, the fact that SpaceX is apparently building full-scale, (mostly) functional Starship tank sections from raw materials to the launch pad in a matter of a few weeks is incredibly encouraging for the next-generation rocket development program. As an external observer, it’s certainly disappointing to see an impressive piece of rocket hardware shredded in an evening after weeks of work, but that speed – and SpaceX’s willingness to accept failures at the scale of SN01 – suggests that each prototype is almost unfathomably cheap. Unofficial estimates peg the cost of SN01-like Starship prototypes at just several million dollars apiece, while the cost of the raw steel itself is so low that it might as well be negligible.

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Even if it takes SpaceX 5-10 SN01-class failures to mature its South Texas rocket factory into a reliable machine and get to a point of stability and confidence with suborbital Starship flights, the total cost of that trial and error is comically insignificant relative to almost any other rocket development program in history. To be clear, SpaceX might benefit from going a little slower and refining Starship’s prototype design, but it’s impossible to know from an armchair. For now, the best available advice is to simply enjoy the show and view each potential test failure as just another small step along the path to Mars.

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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 and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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Investor's Corner

Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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