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SpaceX churning out Starship Super Heavy booster parts ahead of first stacking

SpaceX is churning out dozens of steel rings to assemble Starship's first Super Heavy booster. (NASASpaceflight - bocachicagal)

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SpaceX is busy churning out dozens of steel rings for Starship’s first Super Heavy booster, the assembly of which CEO Elon Musk says could be just “a few weeks” out.

Significantly more than twice the height of Starship’s main propellant tank and engine section, Super Heavy boosters will stand an incredible 70+ meters (230+ feet) tall once complete – the same height or taller than an entire two-stage Falcon 9 or Falcon Heavy rocket. Unlike Starship, Super Heavy will have no conical nose section and will be built – like Starship tanks – entirely out of simple steel rings.

Each measuring 9m (~30 ft) in diameter and 1.8m (~6 ft) tall, SpaceX will need to stack some 38 of those steel rings to complete Super Heavy’s propellant tanks, interstage, and engine section. Impressively, SpaceX is making so much progress building Super Heavy subsections that the start of the first booster assembly will likely have to wait until a facility (“high bay”) tall enough is ready to stack them.

SpaceX is churning out dozens of steel rings to assemble Starship’s first Super Heavy booster. (NASASpaceflight – bocachicagal)

Thanks to handy labels affixed to each ring group and the watchful eye of local resident and photographer Mary (also known as BocaChicaGal), no less than six confirmed sections of the first Super Heavy booster (SH1) have already been spotted in Boca Chica. Ranging from two to four rings tall, the first of those ring sections was spotted on September 22nd, followed by another on the 28th.

The first Super Heavy rings were spotted on September 22nd. (NASASpaceflight – bocachicagal)

Within the first few days of October, that doubled to four, five, and six confirmed stacks, as well as several more likely candidates with labels hidden from publicly accessible viewpoints. Additionally, Musk’s recent note that the liquid oxygen tank of Super Heavy boosters will have “longitudinal stiffeners” – also known as stringers – meant that a trio of five-ring stacks with said stringers were also candidates for Super Heavy #1.

Assuming one of those three five-ring stacks is reserved for the first functional Starship nose section, SpaceX may already have 30+ Super Heavy rings – of ~38 total – awaiting the completion of high bay construction.

Roughly 80 meters (~260 ft) tall, SpaceX’s Boca Chica high bay is essentially an enclosed gantry crane that will be used to stack and outfit Super Heavy boosters – the final steps of production. SpaceX and its contractors began building the high bay in early July and Musk says that the massive building is just “a few weeks” away from completion. As of October, the structure is essentially complete, as is the wall cladding. Roughly half of the building’s roof is also complete, leaving a small amount of work left before running power, HVAC, and plumbing is all that remains.

Unsurprisingly, the SpaceX CEO also says that the high bay will eventually be outfitted with a “giant gantry crane,” though Super Heavy booster stacking will likely begin before then. In the meantime, there’s a good chance that SpaceX will start stacking Super Heavy subsections in the existing Starship mid bay, hopefully leaving just a few big stacks in the high bay to complete the first booster.

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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 loses Model Y program manager in second blow in single day

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Credit: Tesla Manufacturing

Tesla has lost its Model Y Program Manager, he announced on LinkedIn, marking the second major departure from the company today.

Emmanuel Lamacchia has been in the role for 4 years and 7 months, responsible for the rollout of the all-electric crossover in several markets.

The Model Y became the best-selling vehicle in the world for two years under Lamacchia’s watch, making this a huge loss for the company. However, it seems the decision was made under Lamacchia’s own initiative.

He confirmed his decision on LinkedIn:

“After 8 incredible years, I’m moving on from Tesla.

What a journey it’s been… from leading NPI for Model 3 and Model Y variants to becoming the Vehicle Program Manager for Model Y, the best-selling car in the world!

Leading the All-New Model Y launch was the highlight: converting all 4 factories across 3 continents in just 2 weeks. Something that had never been done before in the auto industry.

To the teams who made this possible: you should be incredibly proud. This achievement belongs to you: the engineers, designers, buyers, and associates in Fremont, Shanghai, Berlin, and Austin who turned an impossible timeline into reality.

Grateful to the leaders who trusted me with programs that stretched my capabilities and to the cross-functional partners who showed me that great solutions come from collaboration, not hierarchy.

Tesla taught me how to move fast without breaking things and how to scale from prototypes to millions of units.

Excited for what’s next. More to share soon.”

It marks the second major program loss for Tesla today, as it also bid farewell to Cybertruck and Model 3 Program Manager Siddhant Awasthi, who said he left voluntarily in “one of the hardest decisions of his life.”

Tesla Cybertruck and Model 3 program manager steps down

Lamacchia was at Tesla for just a shade under eight years, and previously worked for Rolls-Royce for roughly the same amount of time.

After the loss of both Lamacchia and Awasthi today, Tesla has lost a handful of key executives in 2025, including:

  • David Imai, Director of Design
  • David Lau, VP of Software Engineering
  • Mark Westfall, Head of Mechanical Engineering
  • Prashant Menon, Regional Director in India
  • Vineet Mehta, Head of Battery Architecture
  • Omead Afshar, VP/Head of Sales and Manufacturing in North America
  • Milan Kovac, Head of Optimus Team
  • Jenna Ferrua, Director of HR
  • Troy Jones, VP of Sales, Service, and Delivery
  • Pete Bannon, VP of Hardware Engineering
  • Piero Landolfi, Director of Service
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Tesla prepares to expand Giga Texas with new Optimus production plant

Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today.

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Credit: Tesla Optimus | X

Tesla is preparing to expand Gigafactory Texas once again with a brand new facility that will house the eventual manufacturing efforts for Optimus, its humanoid robot.

It is already building some units on a Pilot line at the Fremont Factory in Northern California, but Tesla is planning to build the vast majority of its Optimus project at Gigafactory Texas.

Tesla Optimus gets its latest job, and it’s not in the company’s factories

It will build one million units per year in Fremont, but CEO Elon Musk said the company would build 10 million units every year in Texas at a new building at Giga Texas.

Musk said:

“I think there could be tens of billions of Optimus robots out there. Um, now obviously it’s very important we pay close attention to safety here. Then a 10 million unit uh per year production line here the I don’t know where we’re going to put the 100 million unit production line. on Mars. Maybe on Mars, I don’t know.”

Evidently, Tesla is ready to begin thinking about the production efforts of Optimus beyond a theoretical standpoint and is starting to prepare for the construction of the manufacturing plant on Giga Texas property.

Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today:

Production is still slated for 2027, at least at Gigafactory Texas. As previously mentioned, the company is building some units in Fremont for the time being, at least until subsequent versions of the Optimus project advance.

Tesla has done a great job of advancing Optimus forward, but it also has truly grand expectations for the project.

Musk said it could potentially be the biggest product in the history of the planet, as it will revolutionize the way humans perform tasks, probably eliminating monotonous tasks from everyday life.

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Tesla reveals its first Semi customer after launch

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Credit: Tesla

Tesla revealed its first customer for the all-electric Semi truck after it launches next year. Who it truly is should not be a surprise.

The Semi is going to finally start deliveries to new companies outside of Tesla’s pilot program starting in 2026. The company has been building a dedicated production facility in Reno, Nevada, that has finally taken shape, but Tesla was evidently not finished with the Semi’s development.

Tesla shares rare peek at Semi factory’s interior

Last week at the Annual Shareholder Meeting, Tesla said it had implemented some new designs into the Semi, helping with efficiency, updating its design, and making it a more suitable vehicle for hauling loads, as the changes also helped increase payload.

Tesla has obtained a lengthy list of companies that have committed to implementing the Semi in their own fleets, hoping to bring their logistics lineups up to date with electric powertrains and autonomous technologies.

While it is already operating a pilot program with PepsiCo. and Frito-Lay, Tesla will expand to other businesses, primarily using it internally after its launch.

Head of the Semi program at Tesla, Dan Priestley, said the company would be the first user of the vehicle after its launch next year. It has been using it to a certain extent, but the company has not been able to completely abandon gas haulers.

Instead, it will implement the Semi into its fleet for more sustainable vehicle logistics starting next year:

Tesla has already received orders for the Semi from a variety of large companies, including Walmart, Sysco, Anheuser-Busch, UPS, DHL, J.B. Hunt, among others.

Many analysts see the Tesla Semi as a major contributor to future growth and increasing value within the company, especially from a Wall Street perspective. Some firms say the Semi is one of several near and medium-term contributors to the company increasing its market cap.

Cantor Fitzgerald is just one of those firms, as last week it explicitly listed the Semi as a catalyst.

Analyst Andres Sheppard said, “Overall, we remain bullish on TSLA over the medium to long term. We continue to see meaningful future upside from Energy Storage & Deployment, FSD, Robotaxis/Cybercab, Semis, and Optimus Bots.”

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