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SpaceX bumps Starship booster engine count, ramps up Raptor factory

Elon Musk says that Starship's Super Heavy booster will have 29 - not 28 - Raptor engines. (NASASpaceflight - bocachicagal / Elon Musk)

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SpaceX CEO Elon Musk has confirmed that Starship’s Super Heavy booster will have at least one more engine than expected after hardware spotted at its Boca Chica, Texas factory indicated as much.

Simultaneously, Musk revealed that SpaceX’s Hawthorne, California factory and headquarters is now producing Raptors at a rate that will likely make it the company’s most numerous product (outside of Starlink) in the near future.

Musk says that Super Heavy boosters will “initially” have 29 Raptor engines instead of 28 engines and could even be upgraded to 32 engines down the road. In 2020, the vehicle’s design was updated, dropping from 31 to 28 engines for unknown reasons before SpaceX began work on the first real Super Heavy hardware. Known as BN1 or booster number 1, that rocket was stacked to its full ~70m (~230 ft) height but ultimately turned into a manufacturing pathfinder (i.e. practice) after Super Heavy’s design changed once again.

Who or what has been causing those seemingly endless design changes is unclear but SpaceX is finally at a point where any more major changes will explicitly delay plans for Starship’s inaugural spaceflight – deemed an “orbital test flight” by the company. It remains to be seen if SpaceX will actually attempt to recover the first booster(s) after those initial quasi-orbital test flights but we now have a better idea of what those Super Heavies might look like.

Namely, Musk seems to indicate that even the very first flightworthy prototypes will be outfitted with a full complement of Raptors – seemingly nipping in the bud the possibility of a booster debuting with the fewest possible engines. In the case of the first few initial orbital launch, that means that SpaceX is happy to risk losing 32-35 engines for every single attempt.

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That could imply several things. SpaceX might be extremely confident that early boosters will be recovered. It could have zero faith in the reusability of early flown Raptors, meaning that they’re functionally expendable regardless of the outcome. SpaceX could have also reduced the cost and increased the speed of production to the point that expending dozens of Raptors isn’t a major issue – though ~32 Raptors would cost $8 million even if SpaceX has already hit Musk’s long-term “<$250k” per-engine target.

However, Musk also says that SpaceX has ramped up Raptor production to the point that it’s almost completing one engine every 48 hours – equating to around 180 Raptors per year or a maximum cadence of one expendable three-engine Starship and 29-engine booster launch every nine weeks. At that run rate, Raptor has likely beat out Falcon’s venerable Merlin to become SpaceX’s most-produced rocket engine.

According to NASASpaceflight, SpaceX has already begun work on Raptors with serial numbers in the 150s. Two new Raptor test stands in work at its McGregor development facilities will also reportedly enable an average of one engine qualification every day – enough testing capacity to outfit 6 boosters and 30 Starships (~365 Raptors) per year. In short, SpaceX is well on its way to having the ability to manufacture and power a truly vast fleet of Starships and Super Heavy boosters.

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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Tesla AI5 chip nears completion, Elon Musk teases 9-month development cadence

The Tesla CEO shared his recent insights in a post on social media platform X.

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Credit: Tesla

Tesla’s next-generation AI5 chip is nearly complete, and work on its successor is already underway, as per a recent update from Elon Musk. 

The Tesla CEO shared his recent insights in a post on social media platform X.

Musk details AI chip roadmap

In his post, Elon Musk stated that Tesla’s AI5 chip design is “almost done,” while AI6 has already entered early development. Musk added that Tesla plans to continue iterating rapidly, with AI7, AI8, AI9, and future generations targeting a nine-month design cycle. 

He also noted that Tesla’s in-house chips could become the highest-volume AI processors in the world. Musk framed his update as a recruiting message, encouraging engineers to join Tesla’s AI and chip development teams.

Tesla community member Herbert Ong highlighted the strategic importance of the timeline, noting that faster chip cycles enable quicker learning, faster iteration, and a compounding advantage in AI and autonomy that becomes increasingly difficult for competitors to close.

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AI5 manufacturing takes shape

Musk’s comments align with earlier reporting on AI5’s production plans. In December, it was reported that Samsung is preparing to manufacture Tesla’s AI5 chip, accelerating hiring for experienced engineers to support U.S. production and address complex foundry challenges.

Samsung is one of two suppliers selected for AI5, alongside TSMC. The companies are expected to produce different versions of the AI5 chip, with TSMC reportedly using a 3nm process and Samsung using a 2nm process.

Musk has previously stated that while different foundries translate chip designs into physical silicon in different ways, the goal is for both versions of the Tesla AI5 chip to operate identically. AI5 will succeed Tesla’s current AI4 hardware, formerly known as Hardware 4, and is expected to support the company’s Full Self-Driving system as well as other AI-driven efforts, including Optimus.

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Tesla Model Y and Model 3 named safest vehicles tested by ANCAP in 2025

According to ANCAP in a press release, the Tesla Model Y achieved the highest overall weighted score of any vehicle assessed in 2025.

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Credit: ANCAP

The Tesla Model Y recorded the highest overall safety score of any vehicle tested by ANCAP in 2025. The Tesla Model 3 also delivered strong results, reinforcing the automaker’s safety leadership in Australia and New Zealand.

According to ANCAP in a press release, the Tesla Model Y achieved the highest overall weighted score of any vehicle assessed in 2025. ANCAP’s 2025 tests evaluated vehicles across four key pillars: Adult Occupant Protection, Child Occupant Protection, Vulnerable Road User Protection, and Safety Assist technologies.

The Model Y posted consistently strong results in all four categories, distinguishing itself through a system-based safety approach that combines structural crash protection with advanced driver-assistance features such as autonomous emergency braking, lane support, and driver monitoring. 

This marked the second time the Model Y has topped ANCAP’s annual safety rankings. The Model Y’s previous version was also ANCAP’s top performer in 2022.

The Tesla Model 3 also delivered a strong performance in ANCAP’s 2025 tests, contributing to Tesla’s broader safety presence across segments. Similar to the Model Y, the Model 3 also earned impressive scores across the ANCAP’s four pillars. This made the vehicle the top performer in the Medium Car category.  

ANCAP Chief Executive Officer Carla Hoorweg stated that the results highlight a growing industry shift toward integrated safety design, with improvements in technologies such as autonomous emergency braking and lane support translating into meaningful real-world protection.

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“ANCAP’s testing continues to reinforce a clear message: the safest vehicles are those designed with safety as a system, not a checklist. The top performers this year delivered consistent results across physical crash protection, crash avoidance and vulnerable road user safety, rather than relying on strength in a single area.

“We are also seeing increasing alignment between ANCAP’s test requirements and the safety technologies that genuinely matter on Australian and New Zealand roads. Improvements in autonomous emergency braking, lane support, and driver monitoring systems are translating into more robust protection,” Hoorweg said.

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Tesla Sweden uses Megapack battery to bypass unions’ Supercharger blockade

Just before Christmas, Tesla went live with a new charging station in Arlandastad, outside Stockholm, by powering it with a Tesla Megapack battery.

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Credit: Tesla Charging/X

Tesla Sweden has successfully launched a new Supercharger station despite an ongoing blockade by Swedish unions, using on-site Megapack batteries instead of traditional grid connections. The workaround has allowed the Supercharger to operate without direct access to Sweden’s electricity network, which has been effectively frozen by labor action.

Tesla has experienced notable challenges connecting its new charging stations to Sweden’s power grid due to industrial action led by Seko, a major Swedish trade union, which has blocked all new electrical connections for new Superchargers. On paper, this made the opening of new Supercharger sites almost impossible.

Despite the blockade, Tesla has continued to bring stations online. In Malmö and Södertälje, new Supercharger locations opened after grid operators E.ON and Telge Nät activated the sites. The operators later stated that the connections had been made in error. 

More recently, however, Tesla adopted a different strategy altogether. Just before Christmas, Tesla went live with a new charging station in Arlandastad, outside Stockholm, by powering it with a Tesla Megapack battery, as noted in a Dagens Arbete (DA) report. 

Because the Supercharger station does not rely on a permanent grid connection, Tesla was able to bypass the blocked application process, as noted by Swedish car journalist and YouTuber Peter Esse. He noted that the Arlandastad Supercharger is likely dependent on nearby companies to recharge the batteries, likely through private arrangements.

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Eight new charging stalls have been launched in the Arlandastad site so far, which is a fraction of the originally planned 40 chargers for the location. Still, the fact that Tesla Sweden was able to work around the unions’ efforts once more is impressive, especially since Superchargers are used even by non-Tesla EVs.

Esse noted that Tesla’s Megapack workaround is not as easily replicated in other locations. Arlandastad is unique because neighboring operators already have access to grid power, making it possible for Tesla to source electricity indirectly. Still, Esse noted that the unions’ blockades have not affected sales as much.

“Many want Tesla to lose sales due to the union blockades. But you have to remember that sales are falling from 2024, when Tesla sold a record number of cars in Sweden. That year, the unions also had blockades against Tesla. So for Tesla as a charging operator, it is devastating. But for Tesla as a car company, it does not matter in terms of sales volumes. People charge their cars where there is an opportunity, usually at home,” Esse noted. 

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