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SpaceX will build and launch Starship/Super Heavy in Texas and Florida, says Musk

A rough visualization of the size of Starhopper, Starship, and Super Heavy. (Austin Barnard)

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According to SpaceX CEO Elon Musk, the company has plans to both build and launch BFR’s Starship upper stages and Super Heavy boosters at facilities located in Boca Chica, Texas and Cape Canaveral, Florida.

Indicative of SpaceX and Musk’s rapidly evolving plans for the next-generation, ultra-reusable launch system, the to stainless steel over carbon composites appears to continue to have a range of trickle-down consequences (or benefits) throughout the rocket’s design, production, launch, and operations. Given the 3+ radical, clean-sheet design changes the BFR program has undergone in about as many years, it’s hard to definitively conclude much about the latest iteration. Nevertheless, Musk’s indication that stainless steel BFRs may now be built simultaneously at multiple locations suggests that the construction of steel Starships and Super Heavies could be radically easier (and cheaper) than their composite predecessors.

Over the last several months, SpaceX’s manufacturing plans for the massive Starship and Super Heavy vehicles have effectively been up in the air from a public perspective. Official statements provided in January suggested that the first prototypes would be built in-situ after word broke that SpaceX had prematurely terminated a lease with the Port of Los Angeles, where the company had – throughout 2018 – been planning to construct a dedicated seaside BFR factory.

Likely for a variety of reasons, all of which are unknown, SpaceX apparently no longer has a pressing need for dedicated traditional manufacturing facilities at this point in time. Instead, the company is relying extensively on the largely unprecedented practice of building its first suborbital and orbital Starship and Super Heavy vehicles outdoors, much to the visible discomfort of aerospace industry practitioners, followers, and fans alike.

At a bare minimum, SpaceX’s decision to fabricate and assemble large-scale methalox rocket stages with quite literally zero protection from the elements may be one of the most ‘nontraditional’ things the habitually disruptive company has ever done. At the opposite end of the spectrum, building rockets outside could be perceived as an unfathomably foolish endeavor, radically increasing the risk of dangerous manufacturing defects, foreign objects debris (FOD) mitigation, and – ultimately – major vehicle failures. From such an external perspective, wholly lacking any insight from SpaceX itself, it’s difficult to conclude much of anything.

On the one hand, a highly-disciplined adherence to the tenets of best aerospace industry practices and responsible engineering could probably mitigate the risks of en plein air rocket building, particularly if combined with exceptional hardware design optimized for manufacturing, resiliency, reliability, and fault-tolerance. In a perfect world, Elon Musk would be completely aware of all aspects of his companies, while SpaceX’s management would be explicitly focused on encouraging good work and getting the job done right, versus pressuring employees to prioritize speed and low costs over quality. On the opposite hand, it seems unlikely that the former scenario could be made compatible with management and workers capable of failing to do something as simply as safely protecting valuable flight hardware from wind damage.

According to CEO Elon Musk, this large metal cylinder is actually one of the barrel sections of the first orbital Starship prototype. Workers are welding the sections together outside, rain or shine. (NASASpaceflight – bocachicagal)
SpaceX began testing the first (suborbital) Starship prototype around March 14th, likely involving loading the vehicle’s tanks with liquid nitrogen to verify structural integrity and check for leaks. (NASASpaceflight – bocachicagal)

Given that the production of orbital-class, super-heavy lift rockets has really only been attempted twice (Saturn V and Russia’s N1), both times with custom-built, environmentally-controlled factories, it’s likely that SpaceX is already suffering from the inherent uncertainty of the tasks at hand; forging new ground – especially in highly technical fields – is rarely easy or forgiving. Given the aforementioned challenges of building large and reliable rockets at all, challenges that regularly topple vehicles built in traditional factories, it will likely remain an open question if SpaceX can consistently build reliable, technologically-advanced rockets and spacecraft outside until those vehicles have quite literally proven themselves in orbit.

Difficulties aside, it’s easy to understand why SpaceX (or maybe just Elon) is willing to at least attempt something that has never been done before. If the company could find a way to reliably build complex, high-performance rockets without the need for expensive factories, it could radically change the paradigm of rocketry by reducing the often eye-watering upfront costs of building giant launch vehicles. The ability to build rockets almost independently of dedicated factories or assembly facilities would also allow SpaceX to – as Musk said – build their vehicles where they launch, further minimizing the significant challenges and costs of transporting extremely large structures more than a couple of miles.


Regardless of the major challenges standing between SpaceX and its stainless steel Starship/Super Heavy aspirations, Elon Musk appears to be as confident as ever, frankly stating that Starship’s rate of progress “far exceeds” that of Falcon and Dragon. In other words, the apparent instability of the BFR program may actually end up being to its benefit, potentially resulting in a finished product that simultaneously takes less time to come to fruition and is ultimately much closer to its original design intent. At risk of putting the wrong words into Musk’s mouth, it seems that he believes that SpaceX might be able to arrive at a Starship/Super Heavy combo much closer to Falcon 9 Block 5 than Falcon 9 V1.0 and do so far sooner than most believe is possible.

Only time will tell. In the meantime, there will be plenty of fireworks, beginning as early as this week with the first static fire test – and potential hops – of SpaceX’s massive Starship Hopper. Stay tuned for updates!

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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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SpaceX is partnering with chipmakers to enable Starlink satellite-to-cell service

President Gwynne Shotwell outlined the effort during a space industry conference in Paris.

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Credit: SpaceX/X

SpaceX is working with microchip manufacturers to integrate satellite-connectivity hardware into smartphones, advancing its plan for direct-to-device services through Starlink. 

The move follows the company’s $17 billion acquisition of wireless spectrum from EchoStar Corp., a deal that positions SpaceX to operate more independently of traditional telecom carriers. 

President Gwynne Shotwell outlined the effort during a space industry conference in Paris this week, as noted in a Bloomberg News report.

Starlink direct-to-device

Starlink currently serves millions of customers in over 100 countries, primarily through ground-based dishes. The company, however, is now expanding into satellite-to-cell service, which should enable unmodified phones to connect directly with orbiting satellites. While SpaceX has a partnership with T-Mobile US, the EchoStar spectrum purchase gives it more control to negotiate with global carriers on its own terms.

“We’re working with chip manufacturers to get the proper chips in phones,” the SpaceX President stated. “We will now be initiating discussions with telcos in a different way now. Now it’s our spectrum, but we want to work with them, almost providing capacity and wholesaling capacity to their customers.”

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The company plans to launch satellites capable of supporting its direct-to-device business within two years, with early mobile phone testing expected by late 2026.

Starship program continues test flights

Shotwell also addressed SpaceX’s Starship program, which recently completed its 10th test flight in August. She said the mission met all objectives, providing a critical morale boost to teams after a challenging development year. 

“My Starship team needed that win,” Shotwell noted. “Development programs always are kind of a 24/7 operation, and I was really pleased for them.”

SpaceX is planning to fly one more iteration of the current Starship prototype, known as V2, before transitioning to the next-generation V3 vehicle. That version, expected to debut late this year or early 2026, is designed to be more capable and support eventual crewed missions to the Moon and Mars. 

“The V3, which we want to fly hopefully late this year, but maybe early next year, is really the vehicle that could take humans to the moon and Mars,” Shotwell stated.

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U.S. Judge dismisses lawsuit against SpaceX Starship Boca Chica launch site

The ruling found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

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(Credit: SpaceX)

A U.S. district court judge has dismissed a lawsuit brought by conservation groups challenging the Federal Aviation Administration’s approval of SpaceX’s expanded rocket launch operations in Boca Chica, Texas. 

The ruling, issued Monday, found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

FAA review withstands legal challenge

The lawsuit centered on whether the FAA properly assessed the impact of SpaceX’s operations on endangered wildlife, including ocelots, jaguarundis, and Kemp’s Ridley sea turtles, as noted in a report from The Guardian. The plaintiffs argued that noise, light pollution, and construction activity degraded the surrounding habitat, which also serves as nesting grounds for threatened shorebirds.

The lawsuit cited SpaceX’s April 2023 Starship test, which destroyed its launchpad and scattered debris across a large area. The blast reportedly ignited a grassfire and damaged wildlife habitats, including a bobwhite quail nest.

Judge Carl Nichols, for his part, ruled that the FAA had satisfied its obligation“to take a hard look at the effects of light on nearby wildlife.” The decision effectively cleared a regulatory hurdle for SpaceX, which has been working to expand Starship launch activity at its Boca Chica facility.

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A continued ramp

SpaceX continues to scale its operations nationwide. Beyond Starship, the company is also seeking approval to nearly double Falcon rocket launches from Vandenberg Space Force Base in California, from 50 annually to 95. 

Former President Trump has also shared his intention to increase U.S. launch capacity, setting a target for substantial growth by 2030. Considering that SpaceX is by far the world’s dominant launch provider, Trump’s support for more launches will likely benefit the private space company.

For now, at least, the ruling should allow continued expansion at a time when Starship remains central to long-term goals such as Mars missions and NASA’s Artemis program.

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Elon Musk

SpaceX to expand Central Texas facility with $8M Bastrop project

Bastrop is already the site of several Elon Musk-led ventures.

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Credit: SpaceX

SpaceX is set to expand its presence in Central Texas with an $8 million project to enlarge its Bastrop facility, as per state filings. 

The 80,000-square-foot addition, which is scheduled to begin construction on September 24 and wrap in early January 2026, was registered with the Texas Department of Licensing and Regulation and initially reported by My San Antonio

New investment

Bastrop is already the site of several Elon Musk-led ventures. The upcoming expansion will extend SpaceX’s office at 858 FM 1209, near Starlink’s operations and The Boring Company’s facilities. Just down the road, X is housed in the Hyperloop Plaza at 865 FM 1209.

SpaceX’s expansion reflects a steady buildup of resources in Bastrop since the private space firm established its presence in the area. The addition was praised by Tesla Governor Greg Abbott, who wrote on X that the expansion will “bring more jobs, innovations and will strengthen Starlink’s impact worldwide.” 

State support

In March, Gov. Greg Abbott announced a $17.3 million state grant to SpaceX for an “expansion of their semiconductor research and development (R&D) and advanced packaging facility in Bastrop.” The project is expected to create more than 400 new jobs and generate over $280 million in capital investment.

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Following the grant award, the Texas Governor also noted that SpaceX’s facility would be growing by 1 million square feet across three years to boost its Starlink program. SpaceX’s Starlink division is among the company’s fastest-growing segments, with the satellite internet system connecting over 6 million users and counting worldwide. 

Recent reports have also indicated that Starlink has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses. This should pave the way for Starlink to provide 5G coverage worldwide, even in remote areas. 

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