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SpaceX Starbase construction takes priority as next orbital Starship, Super Heavy pair come together

A sea of steel waits to become Starships and Super Heavy boosters. (NASASpaceflight - bocachicagal)

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As SpaceX teams slowly prepare the first orbital-class Starship and Super Heavy booster for the next-generation rocket’s first full-stack launch, the company has simultaneously begun assembling a second ship/booster pair. However, it’s clear that orbital pad construction remains a priority.

Known as Ship 20 and Booster 4, the two stages of the first orbital-class Starship first arrived at the launch site in early August. Only eight weeks later has Starship S20 finally become the first of the pair to attempt and complete one of two crucial proof tests, opening the door for one or several Raptor static fires in the coming week or two. Meanwhile, Booster 4 has had all 29 of its Raptor engines installed, uninstalled, and reinstalled and twice been placed on and removed from Starbase’s orbital launch mount in the same time frame but has yet to attempt any proof testing.

Despite the apparent delays and challenges slowing Ship 20 and Booster 4’s test debuts and two plodding FAA reviews that appear all but guaranteed to preclude an orbital launch attempt in 2021, though, SpaceX has recently begun assembling a second two-stage Starship.

Save for Starhopper back in 2019, no Starship or Super Heavy prototype has spent nearly as long at the launch site without a single test as Ship 20 and Booster 4 have. To an extent, there have likely been some technical delays while assembling, outfitting, and working with two first-of-their-kind prototypes. Still, the difference between past vehicles like Starship SN15 and Super Heavy Booster 3 are so stark that some portion of the testing delays almost has to be a conscious decision made by SpaceX.

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To be able to fully proof and static fire test Super Heavy B4, SpaceX first needs to plumb, wire, and outfit Starbase’s orbital launch mount and complete a majority of the orbital pad’s massive tank farm. However, the orbital pad and its many unfinished systems are situated just a thousand (~300m) east of the suborbital launch site and Starship test facilities, which are complete and ready for testing. To test a Starship at those facilities, SpaceX has to entirely clear the pad of personnel – now several hundred people at the peak of construction – for 6-12+ hours.

The implication is that SpaceX management effectively chose to rip off the bandage now rather than later, sacrificing timely testing of Starship S20 to allow a near-total focus on orbital pad construction and activation over the last ~8 weeks. It’s hard to say if that’s paid off but the fact that SpaceX has chosen this particular moment to begin assembling the next orbital-class Starship and Super Heavy suggests that a clearer plan is starting to come together.

B4/S20, meet B5/S21

Parts of Starship S21 and Super Heavy B5 have been floating around Starbase’s build site for weeks. There was a multi-week period, for example, where the site’s massive high bay was effectively unused – clearly a conscious choice given SpaceX’s history of Starship prototype production earlier this year and late last. Parts of Super Heavy B5 were likely ready for assembly (i.e. stacking) by mid to late August. The ‘mid bay’ used for Starship tank section assembly has been similarly underutilized for even longer – only recently accepting its first Starship S21 section after supporting assembly of the orbital pad’s final storage tank.

Booster 5 is roughly half-finished.

Instead, Booster 5 stacking began around September 15th. At the current rate of assembly, which has slowed down considerably in the last week, SpaceX’s second flightworthy Super Heavy could reach its full 69m (~225 ft) height as early as mid-October. Starship S20 likely won’t be far behind. Further, thanks to SpaceX’s preferred style of continuous improvement, Booster 5 and Ship 21 production already appear well on track to outpace Booster 4 and Ship 20. With B5, rather than installing a range of external equipment (avionics, wiring, plumbing) after assembly is finished, SpaceX appears to be completing some of those subsystems during stacking, potentially speeding up final assembly by 1-2+ weeks. With S21, SpaceX has begun outfitting the Starship’s nose cone with heat shield tiles far earlier in the assembly process than it did with S20.

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Nine days of heat shield work on Ship 21’s nosecone. (NASASpaceflight – bocachicagal)
A tiled section of Ship 21’s propellant tanks. (NASASpaceflight – bocachicagal)
Ship 21’s engine section was recently stacked on top of its skirt section. (NASASpaceflight – bocachicagal)

Given that it has taken SpaceX the better part of a month to finish and spot-fix Starship S20’s heat shield since the prototype’s second trip to the test site, taking those lessons learned to heart and getting Starship S21’s heat shield installation right on the first try could cut weeks from final assembly.

In the meantime, after completing Ship 20’s first cryoproof test on September 29th, SpaceX will hopefully be able to kick off the first six-engine Raptor static fire test campaign within the next week or so. With any luck, the start of B5/S21 assembly also means that the orbital launch pad is nearly ready to support Super Heavy B4’s first proof tests, even if static fires with anything close to a full set of 29 Raptors appear to be weeks away. Regardless, it looks like it won’t be long before SpaceX will be juggling two pairs of orbital-class 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 stuns with another FSD approval in Europe, its second in two days

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Tesla has stunned by gaining yet another approval for its Full Self-Driving suite in Europe, its second in two days and its fifth overall.

Belgium will be the latest country to allow Tesla owners to utilize FSD on public roads in Europe, joining a quickly growing list that started with the Netherlands, Lithuania, and Estonia.

On Tuesday, Denmark announced its approval of the FSD suite, which has now been followed by Belgium just one day later.

The country’s Minister of Mobility, Annick De Ridder, announced the approval on her X account, stating that she had just signed the approval of Tesla FSD. It now goes to the country’s homologation department for the last step of the approval process.

The Belgian approval is one of mighty importance because it truly shows how quickly countries in Europe could greenlight the FSD suite consecutively. Approvals are already coming in relatively quickly, which is a great sign.

Perhaps the next big development that could come from FSD approvals in Europe is an approval from a country like England, Italy, France, Spain, or Germany. It would be something to see how FSD would perform in a major European metro, such as London, Barcelona, Madrid, Paris, Rome, or Berlin.

Full Self-Driving does an excellent job of roaming around major U.S. cities like New York and Los Angeles, but other high-profile international cities of significance would truly mark a line in the sand for Tesla, which can simply enable any vehicle in its customer-owned fleet to run FSD with the correct approvals.

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Elon Musk

SpaceX’s Elon Musk relieves worries about orbital data centers

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Rendering of Elon Musk overlooking a Starship fleet (Credit: Grok)
Rendering of Elon Musk overlooking a Starship fleet (Credit: Grok)

SpaceX CEO Elon Musk recently confronted worries about orbital data centers and launching satellites in mass quantities in space, as some voiced concerns about crowding.

Musk’s SpaceX plans to combat the issue of needing data centers by launching them into space instead of taking up valuable real estate on Earth. It has been a major point of SpaceX’s future, including its looming IPO, which could be the largest ever.

In a recent interview filmed at SpaceX’s Starlink terminal factory in Bastrop, Texas, Elon Musk directly addressed concerns that deploying large numbers of AI satellites for orbital data centers could crowd Earth’s orbit. His message was straightforward and reassuring: space is vast beyond human intuition.

“Space is really big,” Musk said. “It’s not like space is gonna get crowded. Space is enormous. If you actually look at it relative to the Earth, the satellites are so tiny you can’t even see them.” He emphasized that even zooming in makes a satellite appear large, but from a planetary perspective, they are minuscule specks.

Musk pointed to SpaceX’s real-world experience operating roughly 10,000 Starlink satellites as evidence that large constellations can be managed safely. “We’ve got a pretty good idea of how to operate just really large constellations and do it safely,” he noted. SpaceX remains the only operator with meaningful experience at this scale, giving the company unique insight into tight orbital packing without compromising safety

The discussion highlighted SpaceX’s plans for “AI1” satellites—essentially orbiting racks of AI compute powered by massive solar arrays and cooled via radiative panels in space’s vacuum.

These satellites leverage proven Starlink V3 technology, making them simpler to design than communications satellites. A first-generation unit targets around 150 kW peak power, with a 70-meter wingspan for solar panels and radiators. Laser links will connect them to each other and the Starlink network, delivering low-latency access (on the order of a few milliseconds from low-Earth orbit).

FCC accepts SpaceX filing for 1 million orbital data center plan

Musk framed orbital data centers as a practical solution to Earth’s constraints on AI growth. Ground-based facilities face power shortages, water demands for cooling, and grid limitations. In space, constant sunlight (no day-night cycle), vacuum radiative cooling, and abundant solar energy offer clear advantages.

Production will ramp up at an expanded “Gigasat” factory in Bastrop, with solar manufacturing already underway and full AI satellite output expected at reasonable volume by the end of 2027. Starship’s rapid, high-volume launch capability, aiming for multiple flights per hour, will make massive deployment feasible.

Critics sometimes raise risks like space debris or Kessler syndrome, but Musk’s response underscores scale: even a million satellites would represent an imperceptible fraction of available orbital volume when viewed against Earth’s size. SpaceX’s automated collision avoidance and deorbiting designs for Starlink further mitigate concerns.

This vision ties into broader ambitions. Musk sees orbital AI compute as a step toward harnessing more of the Sun’s energy, advancing humanity on the Kardashev scale from a Type 0 civilization toward Type 1 and eventually Type 2. By moving power-hungry data centers off-planet, SpaceX aims to unlock orders-of-magnitude more compute while preserving Earth’s resources.

Musk’s comments should ease public anxiety. With proven operational expertise, incremental engineering, and the immensity of space itself, orbital data centers represent not overcrowding, but smart expansion into the final frontier.

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Investor's Corner

Tesla Full Self-Driving hits Level 4? One analyst says yes

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Credit: Tesla

Tesla Full Self-Driving (Supervised) is currently listed as a Level 2 suite in terms of its passenger cars. As its Robotaxi platform continues to move quickly, it has been recognized as a Level 4 ride-sharing program by the State of Texas, as Tesla recently self-certified itself.

However, a Wall Street analyst is arguing that Tesla (NASDAQ: TSLA) has effectively achieved Level 4 autonomy in most conditions in all of its vehicles, drawing on personal experience and data released by the company.

Alex Potter of Piper Sandler said in a note to investors on Wednesday that “Tesla has solved the self-driving puzzle,” pointing to decisions to offer insurance discounts for FSD-enabled policies as a signal of confidence, which is backed up by stellar safety records compared to human driving.

Investing.com initially reported on Potter’s new note.

Additionally, Potter looks at the recent start of Cybercab production at Giga Texas as a potential indication that Tesla is ready to offer some level of unsupervised driving at least in the near future. The Cybercab has no steering wheel or pedals, completely eliminating the ability for human input.

He also sees Tesla’s allocation of “several hundred million USD (if not $1B+)” as confidence internally, seeing as it would be tough to set aside that amount of capital toward a project that the company does not see as relatively near-term.

Forward thinking, especially as Cybercab has no human controls, it would make sense that Tesla is at least close to self-driving. How close is another question.

Tesla has routinely teased that unsupervised FSD is close, but there are still a lot of things it feels as if the company has to roll out some more capability, including unsupervised parking features, known as “Banish,” better operation with regional self-driving performance, and other improvements.

That is not to say that Tesla FSD is super impressive already. It has already completed coast-to-coast drives across the United States and Canada, it routinely takes the stress out of driving for most people, and it has proven through Tesla Safety Reports that it is safer and involved in accidents less frequently than humans.

Even Potter believes it is capable, as he used it to go from Missoula, Montana, to Minneapolis, Minnesota, back in April.

“There’s no substitute for personal experience,” he wrote.

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