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SpaceX’s next Starship gets frosty to prepare for first launch
One week after the rocket was rolled from the factory to the launch pad, SpaceX appears to have successfully put Starship serial number 9 (SN9) through two routine pre-launch tests.
On December 22nd, significantly less than two weeks after Starship SN9 suffered a significant handling or production accident that caused it to tip several degrees and impact the walls of its production facility, SpaceX wrapped up speedy repairs and transported the rocket about 1.5 miles down the road.
In some combination of a minor miracle and Starship’s exceptionally sturdy design, the rocket – standing ~50 meters (~165 ft) tall and weighing around 75 to 100 metric tons (175,000-220,000 lb) – tipped sideways onto two of its four pre-installed flaps. Despite being subjected to off-nominal forces, the far stronger structural mechanisms connecting those flaps to Starship’s main airframe were seemingly unharmed and SpaceX was able to remove and replace the crumpled control surfaces mere days after the incident.
On December 28th, that work began in earnest with what is generally known as an ambient temperature pressure test, filling Starship SN9’s propellant tanks with benign air-temperature nitrogen gas. Used to check for leaks, verify basic vehicle valve and plumbing performance, and ensure a basic level of structural integrity, SN9 appeared to pass its ambient proof test without issue – albeit late in the window.
Testing wrapped up on Monday shortly after the ambient proof and was followed by the main event – a cryogenic proof test – a bit less than a day later on Tuesday. The exterior of Starship SN9 began to develop a coating of frost after SpaceX started loading its oxygen and methane tanks with liquid nitrogen around 2:30 pm CST (UTC-6). While used similarly to verify structural integrity like an ambient pressure test, a ‘cryo proof’ adds the challenge of thermal stresses to ensure that Starship can safely load, hold, and offload supercool liquids.
In SN9’s case, it’s unclear if SpaceX fully or only partially loaded the rocket’s main propellant tanks with liquid nitrogen, while a lack of frost at the tip of its nose implies that the Starship’s smaller liquid oxygen ‘header’ tank wasn’t filled as part of the test. Altogether, Starship should be capable of holding roughly 1200 metric tons of liquid nitrogen if fully loaded.
The lack of SN9’s LOx header tank participation in Tuesday cryo proof testing is intriguing on its own, as it implies that SpaceX will either perform a second cryo proof later this week or is confident enough in LOx header tank and transfer tube performance to forgo any testing. In the latter case, SpaceX would likely just use the build-up to Starship SN9’s first Raptor static fire test as a wet dress rehearsal (WDR) and a cryo proof for the smaller tank system.
According to NASASpaceflight’s managing editor, if Monday and Tuesday’s ambient and cryo proof tests were as uneventful and successful as they seemed, SpaceX may move directly on to triple-Raptor static fire preparations. In a first, Starship SN9 was transported to the launch pad last week with two of three central Raptor engines already installed and had that missing third engine installed within a few days of arrival. SN9 is also the first Starship to attempt its first proof tests with any Raptor – let alone three – installed.
If SpaceX does move directly from cryo proof testing to a three-engine static fire, that will mark another first for the Starship program and signal growing confidence and a desire for speedier preflight tests – both of which will help accelerate flight testing. As of now, SpaceX has yet to cancel a road closure scheduled on Wednesday, December 30th but it’s far more likely that a trio of 8 am to 5 pm CST closures requested on January 4th, 5th, and 6th will host Starship SN9’s first static fire attempt(s). According to NASASpaceflight.com, Starship SN9 is expected to attempt a 12.5 km (~7.8 mi) launch similar or identical to SN8’s as early as a few days after that static fire. Stay tuned for updates!
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
