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SpaceX Starship briefly becomes largest rocket in history – now what’s next?
On August 6th, after a great deal of anticipation, SpaceX stacked a Starship on top of a Super Heavy booster for the first time ever, very briefly assembling the largest rocket in history.
However, barely an hour after the two stages were integrated and (presumably) latched together, SpaceX lifted Starship (S20) off the booster, returned it to its transport stand, and rolled the ship back to the build site later that day. Though an extreme sensitivity to wind conditions has delayed the procedure, Super Heavy Booster 4 (B4) also appears to be on track to be removed from the orbital launch mount and sent either back to the factory or to a suborbital launch mount that’s been modified for booster testing.
For those that followed the process closely in the days and weeks prior, the fact that Starship’s first full assembly was just a fit check (and, really, more like 50:50 between fit check and photo op) came as no surprise. In the lead-up, it became clear through several reports that CEO Elon Musk had challenged SpaceX to stack Ship 20 and Booster 4 by August 5th and flown in several hundred employees normally stationed elsewhere to accomplish the feat.
Ignoring weather delays that prevented stacking on August 5th, SpaceX met Musk’s challenge in all but the literal sense, assembling the world’s largest rocket into one integrated stack for the first time ever. Even more significantly, despite the fact that SpaceX could have easily decided to stack two not-for-flight prototypes to sort of achieve the same feat, both stages – Ship 20 and Booster 4 – involved in the August 6th milestone are nominally destined for flight.
Barring surprises, the same exact pair is scheduled to support Starship’s first orbital test flight as early as this year. Before they can be cleared for flight, however, a great deal of work must still be completed – work that in some cases is unprecedented in the history of the Starship program.
Not long after the stacking milestone, Musk himself sketched out a few of the tasks still in front of the rocket. Namely, Musk says that SpaceX must still complete Starship S20’s partially-finished heat shield, install some form of heat shield(s) to protect Super Heavy Booster 4’s 29 naked Raptor engines; finish installing, plumbing, and activating 4-7 massive custom propellant storage tanks; and assemble, install, and activate a giant mechanical umbilical arm on the launch tower to fuel and power Starship.
All are undoubtedly crucial and Starship is unlikely to launch before any of them are more or less complete. However, the booster and ship themselves are arguably far more of a pressure point. Before they can be deemed ready for flight, both the ship and booster must complete unprecedented test campaigns on the ground.
Ship 20 will need to complete cryogenic proof testing to verify that the first Starship with six Raptor engine mounts is structurally sound. SpaceX has already modified one of its two suborbital Starship launch mounts for that purpose. Once cryo proof and hydraulic ram testing is complete, those six rams will likely be removed and six Raptor engines will be installed in their place, potentially setting up Ship 20 to become the first Starship prototype to static fire six engines – and any number of Raptor Vacuum engines.
Super Heavy Booster 4 will be faced with an even more ambitious static fire test campaign as SpaceX likely gradually installs more and more engines. Depending on how focused SpaceX is on speed over thoroughness, that process could involve gradually adding 2-5 engines after every static fire or could result in SpaceX starting with 4-9 engines and then immediately jumping from 9 to a full 29-Raptor static fire.
Only after completing those crucial qualification tests is SpaceX likely to stack Ship 20 and Booster 4 for a second time and enter the first true full-stack Starship launch flow – hopefully culminating in the first orbital launch attempt later this year, but only as soon as the FAA completes an environmental review and approves the rocket’s launch license. Technically, FAA approval could come next month or it could take the agency a year or more – it’s almost impossible to predict without official information. However, given SpaceX’s track record with Starship prototypes and Booster B3, it’s likely that a flightworthy Starship and Super Heavy will be stacked on the pad and ready to launch just a few months from now.
Stay tuned for updates on that potential standoff in the making and Starship’s progress towards its first orbital test flight.
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Lifestyle
Tesla app update makes Robotaxi ownership make a lot more sense
Tesla’s app now shows a live indicator when your car is actively driving itself.
A recent Tesla app update, released last week (4.58.5), gives visibility on whether a vehicle is navigating in its semi-autonomous mode or being drive by a human driver. The updated app now displays a live “Self-Driving” indicator in bright blue text directly beneath the vehicle’s speed readout whenever Full Self-Driving is actively engaged, along with the signature glowing blue navigation path that FSD users see on the main touchscreen. It is a small visual update with meaningful implications for how Tesla owners monitor their vehicles remotely.
The feature was first spotted in the wild by X user Jordan Camina, who shared video of a Hardware 3 Model S displaying the new animation through the app while driving. That detail is significant because it confirms the update is not limited to newer HW4 vehicles. It works across hardware generations, and Tesla confirmed it will eventually support all vehicles regardless of chip platform once both the app and vehicle software are updated. The vehicle side requires software version 2026.20.6.1, which has reached nearly 40% of the fleet so far, as monitored by NotaTeslaApp.
The feature makes the most practical sense when viewed through the lens of Tesla’s expanding robotaxi operation. In a robotaxi context, the owner of a vehicle generating ride revenue has a direct financial and safety interest in knowing whether their car is operating under autonomous control at any given moment. The app’s new FSD indicator gives fleet owners exactly that visibility, the same way a logistics company monitors whether a delivery driver is following the planned route. It also carries implications for Tesla’s insurance model. Tesla’s own insurance product prices premiums in part based on FSD engagement rates, and real-time visibility into when FSD is active creates a feedback loop that could eventually tie directly into policy pricing. For individual owners who have opted their personal vehicles into the robotaxi network, the update effectively turns the Tesla app into a fleet management dashboard, one that tells you whether your car is earning money, whether it is driving itself to do it, and whether everything is operating the way it should from wherever you happen to be.
Tesla expands Robotaxi to Florida, marking its third state for autonomy
As Teslarati has reported, Tesla launched unsupervised robotaxi rides in Miami this summer, a milestone that makes a remote FSD status indicator significantly more practical than a cosmetic feature. When a vehicle is operating as a robotaxi without a driver present, the owner or fleet operator needs a reliable way to confirm autonomy is engaged. The app now provides exactly that.
As noted by NotATeslaApp, The update also arrived alongside a hint buried in the same app version that Tesla plans to use the cabin camera to verify driver identity before FSD can be activated. Pairing identity verification with a live autonomy status indicator points toward the infrastructure Tesla is building for a fleet of driverless vehicles that owners can monitor the way you would track a package delivery.
Tesla battery recycling efforts increased 20 percent last year
Tesla FSD is about to know your specific house and neighborhood better than any map
