News
SpaceX files Starship flight debut paperwork, preps for launch pad upgrades
On September 9th, the first signs of SpaceX planning for Starship Mk1’s South Texas launch debut appeared in the form of FCC applications, requesting permission to communicate with the rocket prototype during its first flight.
Simultaneously, word broke on September 5th – via a Business Insider report – that SpaceX is effectively set to receive FAA permission to upgrade its South Texas launch facilities for Starship. All things considered, it appears that most – if not all – the stars have begun to align for SpaceX’s inaugural Starship launch, said by CEO Elon Musk to be scheduled for no earlier than October 2019.
The application confirms several details about Starship Mk1’s debut, revealing that SpaceX will kick off the test campaign with a running jump from Starhopper’s 150m (500 ft) flight-test hand-off. The company is targeting an altitude of ~20 km (12.5 mi) – more than two magnitudes higher than its predecessor’s peak – and plans to land the spacecraft just a hundred or so feet from its launch site, on the same landing pad used by Starhopper.
SpaceX teams continue to work around the clock to ready Starship Mk1 for its ambitious flight debut. A new ring segment was stacked on top of the vehicle’s tank section several days ago, while locals also spotted the delivery of one or two new legs/fins, built out of riveted steel. SpaceX’s Boca Chica team continues to struggle to attach Starship’s tip to the rest of its curved nose section, having recently separated the segments for the first time in months.
Preliminary welding of Starship Mk1’s upper (and final) tank dome appears to be complete and technicians are working to integrate the spacecraft’s internal hardware before it can be installed. Meanwhile, a range of new concrete pads have been set and are being outfitted with additional production hardware, likely paving the way for simultaneously Starship-Starship or Starship-Super Heavy builds in the near future.
Documents acquired and published on September 5th by Business Insider reporter Dave Mosher touched on the assembly facility’s expansion and provided an excellent overview of SpaceX’s planned upgrades to its Starship launch pad. Retasked from original plans (and approvals) for an additional Falcon 9/Falcon Heavy launch site, the documents confirmed that the FAA has reevaluated its 2014 Environmental Impact Statement (EIS) and is effectively ready to re-permit SpaceX’s Boca Chica facilities in light of its new purpose.
About as classically SpaceX as it gets, the company has already dramatically altered plans and timelines since the FAA even began to reevaluate its launch pad EIS. Discussed as Phases 1-3, SpaceX – barely two months after the FAA’s updated EIS statement – appears to have already completed Phases 1 and 2 (wet dress rehearsals, static fires, and small hops) and doesn’t have public plans for “medium hops” of “30 cm…up to 3 km”. The FAA statement – signed in May 2019 – says that the agency did not have the information necessary to permit Phase 3, involving “engine ignition and thrust to lift the Starship to 100 km, flip the Starship at high altitude, and conduct a reentry and landing.“
This article’s feature photo shows SpaceX’s late-2018/early-2019 imagining of launch site upgrades reportedly needed to support Phase 2 testing. Although extremely similar to what SpaceX has already built in South Texas, some significant changes are definitely present, and it looks like SpaceX has a busy 4-8 weeks of work ahead to complete necessary modifications, including expanded propellant storage, two large walls, and possible underground routing of critical infrastructure.
Ultimately, significant work remains for SpaceX to receive both FAA’s EIS go-ahead and experimental launch permits for Starship Mk1’s first flight. Based on the ~3 weeks it took the FAA to simply extend Starhopper’s existing 25m hop permit to 200m (eventually cut to 150m), it could be quite the uphill battle to jump to a 20 km flight test. For the time being, SpaceX hopes to conduct Starship’s 20-km flight debut as early as October 13th, in line with Musk’s ambitious “October” target.
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A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Lifestyle
Tesla app update makes Robotaxi ownership make a lot more sense
Tesla’s app now shows a live indicator when your car is actively driving itself.
A recent Tesla app update, released last week (4.58.5), gives visibility on whether a vehicle is navigating in its semi-autonomous mode or being drive by a human driver. The updated app now displays a live “Self-Driving” indicator in bright blue text directly beneath the vehicle’s speed readout whenever Full Self-Driving is actively engaged, along with the signature glowing blue navigation path that FSD users see on the main touchscreen. It is a small visual update with meaningful implications for how Tesla owners monitor their vehicles remotely.
The feature was first spotted in the wild by X user Jordan Camina, who shared video of a Hardware 3 Model S displaying the new animation through the app while driving. That detail is significant because it confirms the update is not limited to newer HW4 vehicles. It works across hardware generations, and Tesla confirmed it will eventually support all vehicles regardless of chip platform once both the app and vehicle software are updated. The vehicle side requires software version 2026.20.6.1, which has reached nearly 40% of the fleet so far, as monitored by NotaTeslaApp.
The feature makes the most practical sense when viewed through the lens of Tesla’s expanding robotaxi operation. In a robotaxi context, the owner of a vehicle generating ride revenue has a direct financial and safety interest in knowing whether their car is operating under autonomous control at any given moment. The app’s new FSD indicator gives fleet owners exactly that visibility, the same way a logistics company monitors whether a delivery driver is following the planned route. It also carries implications for Tesla’s insurance model. Tesla’s own insurance product prices premiums in part based on FSD engagement rates, and real-time visibility into when FSD is active creates a feedback loop that could eventually tie directly into policy pricing. For individual owners who have opted their personal vehicles into the robotaxi network, the update effectively turns the Tesla app into a fleet management dashboard, one that tells you whether your car is earning money, whether it is driving itself to do it, and whether everything is operating the way it should from wherever you happen to be.
Tesla expands Robotaxi to Florida, marking its third state for autonomy
As Teslarati has reported, Tesla launched unsupervised robotaxi rides in Miami this summer, a milestone that makes a remote FSD status indicator significantly more practical than a cosmetic feature. When a vehicle is operating as a robotaxi without a driver present, the owner or fleet operator needs a reliable way to confirm autonomy is engaged. The app now provides exactly that.
As noted by NotATeslaApp, The update also arrived alongside a hint buried in the same app version that Tesla plans to use the cabin camera to verify driver identity before FSD can be activated. Pairing identity verification with a live autonomy status indicator points toward the infrastructure Tesla is building for a fleet of driverless vehicles that owners can monitor the way you would track a package delivery.
Tesla battery recycling efforts increased 20 percent last year
Tesla FSD is about to know your specific house and neighborhood better than any map
