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SpaceX’s Starship prototype is looking increasingly rocket-like as hop test pad expands

SpaceX workers began welding Starhopper's upper tank dome cap, perhaps the most rocket-like structure yet installed on the craft. (NASASpaceflight - bocachicagal, 02/05/19)

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As SpaceX’s South Texas operations continue full steam ahead in pursuit of the first integrated hop tests of a full-scale Starship prototype, the company’s Starhopper and its complementary launch/hop pad are dramatically and visibly evolving on a daily basis.

This week’s progress has been signified by the installation of familiar rocket hardware on the Ship and a burst of construction – centered around pipelaying, plumbing, foundation work, and berm-building – at its pad. Just a few hundred miles north of Boca Chica, SpaceX’s team of propulsion engineers and technicians reached their own dramatic milestone, conducting the first static fire of a finalized version of the Raptor engine set to power Starship and Super Heavy (formerly BFR).

A pad fit for a Starhopper

In the last ~10 days alone (Jan 24-Feb 4), SpaceX pad construction workers and contractors transformed the former dirt mound from a generally flat, planed surface with a spattering of shipping containers and building materials into a hive of welding rigs, propellant and water tanks, major plumbing progress, shaped earth, and the beginnings of new concrete foundations. Thanks to local student Austin Barnard’s reliable drone photography, that pad-specific progress can be more properly visualized.

 

Taken on January 24th and February 4th respectively, the devil is definitely in the details when it comes to SpaceX’s prospective Starhopper pad development. Most notable is the progress made with the rapidly developing propellant plant and ground systems infrastructure in the left half of the images, marked by hundreds of feet of freshly-installed piping meant to support the process of fueling Starhopper with liquid methane and oxygen. For a rocket as powerful as Starhopper (even with just three Raptor engines), cooling both the propellant and the concrete launch and landing pad is no less important, visible in the shape of three large water tanks (lefthand foreground) and a smaller radiator stack (just to the right of two taller, skinnier white tanks.

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Aside from the rapid rise of the first BFR propellant farm and its supporting equipment, SpaceX has progressed into the installation of a trio of concrete foundations just to the right of the dirt berm and propellant tank area. Standing as close as it is to said propellant tanks, it seems unlikely that the new foundation-laying is related to the pad (or a stand) meant to support early Starhopper hop tests, although SpaceX’s Falcon 9-era Grasshopper and F9R hop test vehicles operated about the same distance from its propellant infrastructure. SpaceX’s South Texas site also features a sort of satellite pad at its east end (the right side in attached photos) that could have a future as an integration hangar or a secondary landing zone to allow for Starhopper to perform divert tests.

 

Depending on whether SpaceX actually intends to develop the land shown above into an actual full-scale launch facility for BFR (Super Heavy and Starship), it could also remain generally unchanged until Starhopper’s hop test program has been run to completion, at which point everything seen above would likely be rebuilt from scratch to accommodate for any drastic changes in function. SpaceX’s Boca Chica might simply be too small to support a pad capable of launching Super Heavy (nearly twice as powerful as Saturn V at full thrust), measuring in at considerably less than ~10 acres of usable area compared to LC-40’s ~20 acres and Pad 39A’s ~50+ acres. CEO Elon Musk has also hinted at using a giant floating platform for early orbital BFR launches, although that might prove even harder (and more costly) than building a traditional land-based pad.

Becoming a rocket

Meanwhile, the aft engine/fin/tank section of SpaceX’s Starship prototype (unofficially nicknamed Starhopper) has experienced a stream of hardware additions and improvements, modifying its relatively awkward and unfinished steel base with what appear to be Falcon 9-sized quick-disconnect umbilical panels, a functional propellant tank header, and mounting hardware for carbon-overwrapped pressure vessels (COPVs). By using hardware that is proven and easy to manufacture, SpaceX can save a huge amount of time that would otherwise need to be spent engineering subassemblies that (at risk of undervaluing the challenge) are generally known-quantities – more a matter of time and effort than an actual technical hurdle.

 

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While they are clearly still in a rough, unfinished form, Starhopper’s umbilical panels are already easy to recognize when compared alongside Falcon 9’s iconic red and blue panel pairs. In essence, whereas Starhopper has been a largely unknown quantity with no familiar aspects since it began to come together late last year, the Starship prototype has recently had hardware installed that is finally revealing subtle SpaceX signatures in its design and assembly.


Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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.

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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.

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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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