News
SpaceX Starship Integrated Flight Test 2: What to Expect
After a one-day delay to replace a failed grid fin actuator, SpaceX is now less than 24 hours from the second test flight of Starship. SpaceX will have a 20-minute launch window that opens at 7:00 AM CT (13:00 UTC).
Making this test flight is Ship 25 and Booster 9. Ship 25 is powered by 6 Raptor engines (3 sea level and 3 vacuum), and Booster 9 is powered by 33 Raptor engines.
Booster 9 features many upgrades over the last booster to take flight, including better engine shielding and a switch from hydraulic thrust vector controls to electric TVC. Ship 25 didn’t see as many upgrades as the booster, and not much has been shared of any major changes that were made. One change to both vehicles was the improvement of the Flight Termination System, which took much longer to destroy the rocket than expected during the first test.
Launch Day
T minus 2 hours before the scheduled liftoff, the SpaceX launch director will give the go for propellant loading. This process will begin at t minus 1 hour and 37 minutes, and at this point, Booster 9 will begin loading with both liquid oxygen and liquid methane.
T minus 1 hour and 17 minutes, liquid methane will begin loading onto Ship 25, followed by liquid oxygen 4 minutes later at t minus 1 hour and 13 minutes.
T minus 19 minutes and 40 seconds, the 39 Raptor engines on Booster 9 and Ship 25 will begin chilling to prepare for the extremely cold fuel to flow through and prevent thermal shock to engine hardware.
T minus 10 seconds, the flame deflector installed after the first IFT will begin flowing water.
Super Heavy Booster 9 static fire successfully lit all 33 Raptor engines, with all but two running for the full duration. Congratulations to the SpaceX team on this exciting milestone! pic.twitter.com/1hzs768vHg
— SpaceX (@SpaceX) August 25, 2023
T minus 3 seconds, Raptor engine ignition begins, and thrust begins to build to allow for liftoff.
LIFT OFF!
T+ 2 seconds, the 2nd Integrated Flight Test should now be officially underway, with Booster 9 thundering away from the orbital launch mount.
Liftoff from Starbase pic.twitter.com/rgpc2XO7Z9
— SpaceX (@SpaceX) April 20, 2023
T+ 52 seconds, Starship and Booster 9 reach Max Q, the area of maximum dynamic pressure on the vehicle will occur here. If (or most) all Raptor engines on Booster 9 are performing nominally, the vehicle will pass through this fairly quickly.
T+ 2 minutes and 39 seconds, Staging. This will be the first time SpaceX has ever attempted hot staging. Almost all of Booster 9 engines will cut out, and Ship 25 will ignite its Raptor engines to separate from the booster. This is all unknown territory from this point on for SpaceX, as the first test flight did not make it this far. SpaceX has yet to clarify how many Ship 25 engines will ignite during this process.
If all goes well, Booster 9 will begin its flip and boost backburn at t+ 2 minutes and 53 seconds, which will last ~54 seconds. Unlike the Falcon 9, the booster is not designed to perform an entry burn.
T+ 6 minutes and 30 seconds after lift-off, Booster 9 will begin its landing burn for a hopeful soft touchdown in the Gulf of Mexico 18 seconds after landing burn ignition. The planned landing area is ~20 miles (32 km) downrange.
Meanwhile, Ship 25 will continue burning its 6 Raptor engines until t+ 8 minutes and 33 seconds, inserted into a sub-orbital trajectory, and then enter a coast phase until its planned reentry North of the Hawaiian islands.
Landing!
At t+ 1 hour and 17 minutes, Starship will begin feeling the effects of the atmosphere, its first real test for the heatshield. If it survives atmospheric entry, Starship will splash down in the Pacific Ocean at t+ 1 hour and 30 minutes after lift off. SpaceX has said Ship 25 will not attempt a landing burn during this test.
If Starship is able to make it past staging, SpaceX will most likely consider this test a success, but it would be a major accomplishment for Ship 25 to survive entry back through the atmosphere and gather important data for the company.
If you have a chance to make it to South Texas or even the other side of the Rio Grande in Mexico, it’ll be a sight you’ll never forget. If you’re watching from home, SpaceX will begin streaming the launch on X and their website 35 minutes before lift-off.
Questions or comments? Shoot me an email at rangle@teslarati.com, or Tweet me @RDAnglePhoto.
Investor's Corner
New drone video shows Tesla’s Optimus Factory reaching a turning point
New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.
Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.
Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.
Tesla Giga Texas to feature massive Optimus V4 production line
The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.
Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.
Investor's Corner
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.
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.
News
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.
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.