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SpaceX Starship to land NASA astronauts on the Moon

SpaceX has won NASA funding to develop a custom Starship variant designed to land astronauts on the Moon. (SpaceX)

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SpaceX has won part of a new $1 billion NASA contract to create a custom version of Starship designed explicitly to send space agency astronauts and huge amounts of cargo to the Moon.

Incredibly, SpaceX won its Lunar Starship development contract alongside two others awarded by NASA – one to a Blue Origin-led coalition and the other to Dynetics and “more than 25 subcontractors”. Of the three, only SpaceX’s offering is a single-stage lunar lander, while Dynetics wants to build a two-stage lander and Blue Origin wants to build a three-stage lander. It also appears that SpaceX’s custom Starship is the only lander designed to be at least partially reusable, capable of flying “many times between the surface of the Moon and lunar orbit” according to the launch company.

While potentially very exciting, the fate of NASA’s triple-threat Moon lander contract award now rests almost entirely in the hands of Congress. As of today, NASA has committed almost $970 million to the three lunar landers it’s decided to develop, only part of which the space agency appears to have on hand and ready for dispersal. For the program to even begin to approach actual missions to the Moon, let alone astronaut landings, Congress will have to consistently raise NASA’s budget every year for at least the next five to six.

https://twitter.com/JimBridenstine/status/1255902514542718976

Even insofar as that required budget raise (roughly ~$3B per year) is only a 10-15% increase and is effectively a rounding error relative to the rest of the federal budget, military in particular, the odds that Congress will consistently and fully support it are not great. For example, the Commercial Crew Program (CCP) – set to attempt its inaugural astronaut launch next month – began in 2010 with the expectation it would cost around $7-8 billion and achieve its first crewed launch in 2015 or 2016.

From 2010 to 2015, Congress systematically underfunded the Commercial Crew Program for largely parochial reasons, preferring to put money into projects (typically the Space Launch System rocket, Orion spacecraft, and their launch facilities) that directly benefited their districts or states. Over half a decade, Congress supplied only 60% of the funds CCP had budgeted, a lack of resources that likely directly resulted in years of program delays. Notably, while both Boeing and SpaceX have run into significant technical hurdles and suffered their own technical delays, the companies would have almost certainly been able to discover those hurdles earlier on if they’d had the full CCP budget supporting them.

Boeing's Starliner and SpaceX's Crew Dragon spacecraft stand vertical at their respective launch pads in December 2019 and January 2020. Crew Dragon has now performed two successful full-up launches to Starliner's lone partial failure. (Richard Angle)
Boeing’s Starliner and SpaceX’s Crew Dragon spacecraft atop their Atlas V and Falcon 9 rockets. (Richard Angle)

It’s entirely unclear whether NASA’s new Artemis Moon lander program will have a better or worse time than the Commercial Crew Program. The same parochial SLS/Orion/ground systems interests remain in full force in the US House and Senate and will likely not be pleased by the fact that only one of NASA’s three HLS awards could result in SLS launch contracts. Surprise winner Dynetics has proposed a lander that can launch on either SLS 1B or the United Launch Alliance (ULA) Vulcan Centaur rockets.

SpaceX’s Starship lander will unsurprisingly launch of its own Super Heavy rocket booster, while Blue Origin, Lockheed Martin, Northrup Grumman, and Draper’s lander will almost certainly launch on the former company’s New Glenn rocket.

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Starship and Super Heavy. (SpaceX)
New Glenn. (Blue Origin)

Ultimately, this is the most significant acknowledgement and support SpaceX’s next-generation Starship rocket has ever received from NASA or the US federal government. Still, of the ~$970 million NASA has initially committed, Starship only received $135 million – nearly half as much as Dynetic received and more than four times less than Blue Origin’s award. NASA is thus clearly hinging its investment on SpaceX’s continued internal support for its next-generation, fully-reusable launch vehicle, as $135 million certainly isn’t enough for even SpaceX to build a building-sized rocket to land astronauts on the Moon.

Regardless, this is certainly one of the most intriguing possible outcomes of NASA’s Human Lander Systems contracts and should keep things very interesting – pending Congressional support – over the next several years.

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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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.

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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.

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.

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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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