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SpaceX destacks “420” Starship, Super Heavy pair for the third time
Update: Shortly before SpaceX CEO Elon Musk revealed that Super Heavy booster B4 and Starship S20 are no longer assigned to the rocket’s orbital launch debut, the company ‘destacked’ the pair for the third time.
Ship 20 was removed from Booster 4 on March 19th, two days before Musk’s tweets. That’s not unusual: it was actually Ship 20’s third removal from Super Heavy. However, almost as soon as the Starship was rolled out of the way, SpaceX began making visible preparations to also remove Super Heavy B4 from Starbase’s orbital launch mount. As of March 24th, the booster has been attached to a large crane for more than a day and a newly upgraded transport stand has been rolled into place beside the launch mount. It’s somewhat odd that the booster hasn’t already been removed but that step could happen at almost any moment, now – albeit likely in daylight.
Once both Ship 20 and Booster 4 have been removed, it’s hard to imagine that they will ever return to the orbital launch mount. In fact, at minimum, Super Heavy B4 will probably be retired almost immediately. Super Heavy B7 – a superior, refined, and upgraded prototype by almost every measure – is already almost fully assembled and could likely begin basic testing within a week or two.
SpaceX CEO Elon Musk says that Super Heavy Booster B4 and Starship S20 are no longer scheduled to support the first orbital-class test flight of the world’s largest rocket.
Rumors, signs, and reports of the significant change have been flowing among unofficial spaceflight communities for months. Booster 4 and Ship 20 were first confirmed by Elon Musk to be the pair assigned to Starship’s orbital test flight (OTF) in the summer of 2021. When the pair first rolled out to the launch pad in early August, Musk seemed confident that they could be ready for an orbital launch attempt within a month or two. The same was true in November 2021, when Musk stated that the same Starship and Super Heavy pair could be ready for their first launch as early as January or February 2022.
Musk’s latest update on Starship’s orbital test flight continues that schedule optimism but also introduces several major changes – changes that could easily take several months to fully work through.
Crucially, Musk revealed that the first Starship to attempt an orbital-class launch will now feature upgraded Raptor V2 engines – engines that require an entirely new thrust structure design. That already all but guaranteed that B4 and S20 had been overtaken but Musk also explicitly confirmed that they would be replaced with a new pair in a later tweet.
That new pair – widely assumed to be Super Heavy B7 and Starship S24 – feature a wide range of design changes, including substantially modified header tanks, an entirely new nosecone design, new layouts for secondary systems (pressurization, avionics, heat exchangers, etc.), and more. Most importantly, their thrust structures – giant ‘pucks’ machined out of steel – have been tweaked to support new Raptor V2 engines instead of the Raptor V1 and V1.5 engines that have been installed and tested on all Starship and Super Heavy prototypes to date.
Musk believes that SpaceX will be able to build (and presumably qualify) all 39 of the Raptors Ship 24 and Booster 7 will need before the end of April and fully install them – as well as all the heat shield components that must be fitted around them – by the end of May 2022. It’s unclear if the SpaceX CEO is accounting for the extensive proof testing Ship 24 and Booster 7 will likely need to complete before being qualified for flight, including cryogenic proof tests, wet dress rehearsals, and at least a few static fire tests.
In fact, SpaceX has only performed a single three-engine static fire test with a fully outdated Super Heavy prototype. Before the company is confident in its booster design, it’s practically a certainty that one or more prototypes will be put through a lengthy test campaign that gradually evolves from igniting a few engines to igniting all 29 or 33 Raptors. That may actually be one of the reasons SpaceX appears to be retiring Booster 4 without a single static fire or flight test – performing all the requisite work may have ultimately been perceived as a dead-end when every future Starship and Super Heavy prototype will feature a heavily redesigned engine.
This is to say that much like Musk’s last few Starship OTF schedule estimates, May 2022 also appears to be extremely optimistic. Booster 7 could potentially be ready for cryogenic proof testing any day now but Ship 24 is still in five large pieces and probably at least a month from any form of test readiness. Still, there are some reasons for optimism. If Booster 7 actually does start basic proof testing this month or early next without waiting for its Raptor engines or for heat shield installation, SpaceX could theoretically complete cryoproofing, begin installing one or a few new Raptors at a time, and iteratively progress from static firing a few to all 33 engines as the engines are arriving at Starbase.
At a minimum, even if that razor-sharp test schedule isn’t possible, Booster 7 would at least have a month or so of extra testing over Ship 24, minimizing the disproportionate amount of testing each prototype will likely need to be qualified for flight. Unlike Booster 4, Ship 20 has completed several static fires and cryoproofs without any apparent issue.
For now, SpaceX continues to prepare Ship 24 sections for stacking and appears to be buttoning up Booster 7, which could easily be ready to roll out for basic testing within a few weeks – and maybe sooner.
Elon Musk
Tesla reveals Optimus Academy, where robots teach themselves
Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.
Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”
The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.
Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.
The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.
Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.
The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.
Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.
Elon Musk
The Starship moon landing number NASA and Elon Musk can’t agree on
Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.
Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.
On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”
Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”
The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.
Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.
How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.
Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.
Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.
Elon Musk
Tesla’s secretive “Project Crystal Sun” gets a big green light in Texas
Fort Bend County approved four incentive agreements Thursday for Tesla’s proposed $10.1 billion solar factory.
Fort Bend County commissioners on Thursday approved a package of tax incentives for Tesla’s proposed $10.1 billion solar cell factory near Needville, Texas, giving the company one of the last local approvals it needs before it decides where to build. All four Tesla agreements passed 4 to 0.
The votes covered a property tax abatement inside Reinvestment Zone No. 34, a Chapter 381 economic development agreement, a foreign trade zone non-objection paired with payments in lieu of certain taxes, and a separate payment in lieu of taxes “true up” agreement, according to agenda notes from the Fort Bend Commissioners Court meeting.
The project, known internally as “Project Crystal Sun,” would make solar cells and finished modules on roughly 3,000 acres near FM 762 and FM 1994, south of the Brazos River. As Teslarati reported when the filing first surfaced in August, Tesla’s application under the state’s JETI Act splits the investment into $1.5 billion in real property and $8.6 billion in equipment, with 9,712 permanent jobs projected by 2033 and commercial operations targeted for the first quarter of 2029. The plant would handle the full chain from ingot and wafer production through cell testing.
Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing
Thursday’s approval does not lock in the site. Tesla has told the Texas Comptroller it is still weighing other locations, and site selection adviser David Dennison told Lamar Consolidated ISD trustees in September that the race had narrowed to Fort Bend and one out of state rival with a “very compelling package,” according to the Houston Chronicle. Tesla hopes to decide before the end of 2026, and the incentives still need sign off from the Comptroller and the Governor’s office.
Local officials have now done nearly everything within their control. Commissioners created the reinvestment zone in an August 24 special meeting, with Interim County Judge Daniel Wong formally withdrawing himself over his engineering firm’s past work with Tesla. Lamar CISD trustees voted 7 to 0 on September 15 to advance a JETI agreement that would tax Tesla’s qualifying property at 50 percent of its value for maintenance and operations from 2029 through 2038.
The plant lines up with a target Elon Musk set on Tesla’s Q4 2025 earnings call in January, when he said the company would “work toward getting 100 GW a year of solar cell production, integrating across the entire supply chain from raw materials all the way to finished solar panels.” In March, Tesla was reported to be negotiating a $2.9 billion purchase of Chinese solar manufacturing equipment bound for Texas. The Houston area already hosts Tesla’s Megafactory in Brookshire, where Megapack 3 production has started. Tesla said on its Q3 call that Megapack supply for 2027 is nearly sold out, and Musk wrote on X Thursday that the company is “increasing production of Megapacks as much as possible,” as demand from data centers climbs.
Tesla reveals Optimus Academy, where robots teach themselves
The Starship moon landing number NASA and Elon Musk can’t agree on
