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SpaceX rolls next Starship to the launch pad nine days after midair explosion

Starship SN15 is headed to the launch pad nine days after SN11's midair explosion. (NASASpaceflight - bocachicagal)

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Update: Right on schedule, SpaceX has transported Starship serial number 15 (SN15) from its Boca Chica rocket factory to a launch and test site just down the road.

SN15’s pad arrival comes just nine days after Starship SN11 – the last in a batch of four first-generation prototypes – exploded in midair some 30 seconds before a planned landing. While minor, SN11’s midair failure was undoubtedly a step backward relative to Starship SN10, which (briefly) became the first full-size prototype to land in one piece less than a month prior. Both SN8, SN9, and SN10 made it further into their identical flight tests, leaving SN11 somewhat high and dry and putting extra pressure on Starship SN15.

After Starship SN8’s unexpectedly successful December 2020 test flight, in which the rocket made it just a dozen or so seconds away from soft landing after more than six minutes in flight, SpaceX made the decision to scrap Starship SN12 and kill SN13 and SN14 before assembly could begin. Effectively a gamble that SN8-SN11 would produce enough of a foundation for future testing to start off on, it’s hard to say if that gamble paid off.

All four Starship flights managed the extraordinary feat of more than four minutes of powered flight and spent two minutes free-falling like no rocket ever before them, but they also made it clear that both Raptor and autogenous pressurization (using gasified propellant to pressurize Starship’s tanks) are not quite mature enough for reliable launches and landings. Featuring “hundreds of improvements,” many of which were hopefully designed to tackle some of those shortcomings, it’ll be up to Starship SN15 to attempt to carry that torch forward – and, with any luck, further than any prototype before it.

After SpaceX unexpectedly used a Monday road closure to deliver its first custom-built rocket fuel tank, plans for the next Starship test campaign and launch have begun to solidify.

Most importantly, the initial schedule for Starship serial number 15’s (SN15) test campaign appears to be clear. As of Wednesday, April 7th, road closures filed by SpaceX suggest that the first of a new group of upgraded Starships will be transported from build site to launch pad as early as 11am-1:30pm CDT (UTC-5) on Thursday, April 8th. Once SN15 is installed on ‘Suborbital Pad A,’ SpaceX means to waste no time and has scheduled a 7am-12pm road closure on Friday.

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As usual, the weekend will once again be free of any testing or activity requiring road closures, but SpaceX has already cordoned off noon to 8pm on Monday and Tuesday (April 12/13) to continue putting its newest Starship prototype to the test.

SpaceX technicians and engineers work to put the finishing touches on the weld joining Starship SN15’s two halves and remove scaffolding ahead of the rocket’s trip to the launch pad. (NASASpaceflight – bocachicagal)

While road closure notices no longer offer any real detail, a few basic details can still be inferred. The April 7th closure, for example, warns that SpaceX only plans to intermittently close the highway but not Boca Chica Beach – implying that the window poses no threat to residents or beachgoers. Historically, that means that something will be transported – likely Starship SN15, in this case.

On Friday, SpaceX has scheduled a full five-hour closure of both the highway and beach, implying that some kind of testing is likely on the books. The same goes for Monday and Tuesday, but with longer eight-hour closures.

More likely than not, assuming Starship SN15’s pad transport and launch mount installation goes smoothly, SpaceX will use the shorter Friday window to complete a basic ambient pressure test – filling the rocket with ambient-temperature nitrogen gas to test its complex plumbing and propellant tanks for leaks. Continuing the IFF (if and only if) string, SpaceX will then spend the weekend preparing Starship SN15 for a cryogenic proof test and thrust structure stress test – simulating the thrust of three Raptors after loading the rocket with extremely cold liquid nitrogen (LN2).

SpaceX will then most likely spend another one or two days inspecting Starship SN15 and removing the hydraulic ram used to simulated thrust from the launch mount the ship is installed on. Once SN15 and its mount are cleared, SpaceX can move into static fire testing. Given that – according to CEO Elon Musk – SN15 will debut Raptor engines with an unknown degree of upgrades, it’s reasonable to assume that SpaceX will take things relatively slowly and possibly perform more than one static fire test even if the first attempt is a total success.

If not and SpaceX continues to push hard like it did with SN10 and SN11, it’s not out of the question that Starship SN15 will be ready for its first launch attempt around Friday, April 16th or Monday, April 19th. Stay tuned for updates as SpaceX hopefully rolls the rocket to its Boca Chica, Texas launch site later today.

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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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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