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SpaceX stacks Starship nose section for the first time in months
SpaceX has stacked a Starship nosecone section to its full height for the first time in almost a year, featuring an upgraded design that could soon support an ambitious series of flight tests.
Back in August 2019, SpaceX first began stacking the nose section of Starship Mk1 – the first full-scale prototype of any kind. It became clear a few months later that Starship Mk1 was more of a rough proof of concept than a full-fidelity test article, but it still became the first (and only, so far) Starship to reach its full ~50m (~160 ft) height. After serving as a centerpiece during CEO Elon Musk’s September 2019 Starship presentation, SpaceX removed the nose and attempted to test the Mk1 tank section itself, ultimately destroying the ship.
Now eight months distant from Mk1’s demise, SpaceX’s Starship R&D program has entered the prototype mass-production phase. Since January 2020, SpaceX has built five upgraded Starship tank sections (and tested three to destruction), built and tested four stout test tanks, and completed at least 4-5 new nosecone prototypes. For the first time since nosecone production began several months ago, one of the noses has finally been stacked to its full height atop five steel rings.
At the moment, SpaceX is hard at work preparing Starship SN5 for its first wet dress rehearsals (WDRs) with methane and oxygen propellant and either one or several Raptor engine static fire tests. If successful, SpaceX will quickly move to flight test preparations, readying SN5 for a nominal ~150m (~500 ft) hop, though the company is technically no longer restricted to that ceiling. For such a low-altitude test, aerodynamic features like a nosecone or flaps serve no functional purpose, meaning that SN5 is unlikely to ever receive those additions.
Roughly two miles west of the coastal launch and test site SN5 is stationed at, SpaceX has already more or less finished Starship SN6, although the newest ship’s fate is unclear. Pictured above on July 10th, the task of stacking an even newer ship (likely SN8) may already be underway. Last month, SpaceX tested a new ‘test tank’ built out of a different steel alloy said by CEO Elon Musk to be theoretically superior. Two cryogenic pressure tests seemingly confirmed that suspicion, proving that 304L stainless steel fails more gracefully than 301 while still offering similar strength at the pressures Starships operate at. The SN7 test tank was built and tested around the same time as SpaceX was finishing up SN6, implying that the ship was almost certainly built out of 301 steel.
If 304L really is the way forward for future Starship prototypes, the next step will be building an entire ship out of the steel alloy and performing a full cryogenic proof test and wet dress rehearsal. Given that SN5 and SN6 are likely identical (or nearly so), SN6 may have been made redundant before the ship even left the factory floor.
This is all to say that it’s a bit of a mystery where the first upgraded nosecone will find itself in the coming weeks. Like SN6 or SN7, it could either be redundant on arrival, built as practice, or both. It could also be the first nosecone installed on a flightworthy Starship prototype. It’s unlikely but not impossible that SN5 survives its static fires and first hops and is modified to support three Raptors and aerodynamic control surfaces, while SN8 and SN9 are more probable candidates for the first high-altitude, high-velocity test flight(s). SpaceX has at least 3-5 more Starship nosecones strewn about its Boca Chica factory, though, so odds are good that the first new nose section to reach full height won’t be the first to take flight.
For now, Starship SN5 (sans nose) is scheduled to attempt its first wet dress rehearsal (WDR) no earlier than July 16th. If successful, a static fire could follow a few days after that and a hop test another few days later.
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Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
Tesla is expanding its Robotaxi service hours by pushing the time back by one hour, keeping the ride-hailing service operational until 11 p.m., one hour later than previously.
CEO Elon Musk confirmed the change and offered a specific reason the expansion has been gradual: the system still needs to reliably avoid small pets that are difficult to see after dark, as they commonly blend into the color of the road, especially when they’re grey.
The latest adjustment restores only a fraction of the operating window the service once held. When paid Robotaxi rides began in Austin on June 22, 2025, vehicles ran from 6 a.m. to midnight.
In September 2025, Tesla lengthened the day to a 2 a.m. close, producing a 20-hour window that stayed in place for most of the following year. By early August of this year, the cutoff had already been pulled back; an August 26 update formalized hours of 6 a.m. to 10 p.m. across Austin and several other markets.
The October move to 11 p.m. therefore leaves the Austin day one hour shorter than the original launch schedule and three hours shorter than the 2025 peak.
Musk addressed the constraint directly after the announcement. “The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night,” he wrote. “Literally trying to avoid grey kittens on grey tarmac in the dark.”
Robotaxi operating hours moved from 10pm to 11pm.
The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night. Literally trying to avoid grey kittens on grey tarmac in the dark.
— Elon Musk (@elonmusk) October 3, 2026
The example points to a low-contrast perception problem in which a small animal can blend into the road surface under limited lighting.
Tesla’s vehicles rely on cameras and neural-network processing rather than lidar; Musk has previously argued that advanced vision software can extract useful information even in low light by analyzing photon counts, but the pet-detection case remains the stated limiter in later hours.
The modest schedule change arrives alongside faster growth in the purpose-built Cybercab fleet. Texas registration data tracked by observers showed the Austin Cybercab count rising sharply in recent weeks, reaching 169 vehicles after more than 100 were added in a short span.
Tesla has indicated that a broader shift toward 24-hour operation is tied to the upcoming FSD v15 software release expected this month on Robotaxi vehicles. Until that capability is validated for the edge cases Musk described, the company continues to add service time incrementally rather than jumping straight to overnight coverage.
The one-hour extension gives Austin riders a later option for evening trips while the underlying detection work continues.
Elon Musk teases TSMC as potential Terafab partner
Tesla reveals early Robotaxi charging strategy, showing scrappy DNA
