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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.

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.

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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.

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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Elon Musk

Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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Elon Musk

Trump to hand Elon Musk a top honor that traces back to JFK

Trump will award Elon Musk the National Medal of Science at Thursday’s White House summit.

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elon musk and donald trump in front of a tesla cybertruck at the white house

Elon Musk is set to receive the highest honor the U.S. government gives to scientists and engineers.

President Donald Trump will present Musk with the National Medal of Science on Thursday at the White House’s Science: A New Golden Age Summit, Fox News Digital first reported on Wednesday. Google cofounder Sergey Brin, Nvidia CEO Jensen Huang and AMD CEO Lisa Su will receive the same medal, while Dell Technologies CEO Michael Dell and Microsoft CEO Satya Nadella will receive the National Medal of Technology and Innovation. A White House official later confirmed the list to Reuters.

“The Trump administration is grateful for the contributions of these incredible leaders in science and technology. These recipients are helping ensure America keeps leading the world in innovation,” White House spokesperson Liz Huston told Fox News.

It will be the first time Trump has presented either medal in his two terms. Congress created the National Medal of Science in 1959, and the National Science Foundation, which administers it, says 529 scientists and engineers have received it since. A presidential committee reviews nominees, but the president makes the final call.

Thursday’s group of medalists run or founded companies, and three of them sit at the center of the Super Intelligence hardware race that Musk competes in. Huang’s Nvidia supplies the GB300 chips filling SpaceX’s Colossus 2 cluster, while Su’s AMD is Nvidia’s biggest rival in data center GPUs.

Worth noting that Trump’s uncle, MIT physicist John G. Trump, received the National Medal of Science from President Ronald Reagan for his work on ionizing radiation and its uses in medicine and industry.

The Pentagon taps Elon Musk to design the battlefield of the future

For Musk, the medal is the latest sign of how far his relationship with Trump has come since their 2025 split over the “Big Beautiful Bill” and his exit from DOGE. Last week, he sat at Trump’s left during a White House lunch where AI executives signed a voluntary safety accord, and Defense Secretary Pete Hegseth named him to help lead the Pentagon’s Project Meridian study on the future of warfare. Musk has also adopted the administration’s new vocabulary, saying on Sunday that SpaceXAI will be renamed SpaceXSI after Trump ordered federal agencies to replace “artificial intelligence” with “super intelligence.”

Musk has collected science honors before, including the Stephen Hawking Medal for Science Communication in 2019.

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Tesla FSD changed its mind mid-intersection, and it may have saved a life

Tesla shares dashcam footage of FSD Supervised stopping mid intersection to avoid a T-bone crash.

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Credit: @BLKMDL3/X

Tesla is putting another Full Self-Driving save in front of its 24.8 million followers on X.

On Tuesday morning, Tesla’s main account shared a dashcam clip with the caption “FSD Supervised preventing T-bone crash.” The footage came from an owner posting as TheNewGrid, who described what happened at a stop sign: “I looked at the car coming to the stop sign figured they would stop, my car went, then came to a stop mid intersection as they flew by. Had I been manually driving this would have resulted in a crash.”

The sequence is the notable part. FSD had already started crossing when the other driver ran the stop sign. Instead of pressing on, the car braked hard in the middle of the intersection and let the crossing vehicle pass in front of it. By the owner’s own account, they had made the same assumption the software initially made, that the other car would stop, and would not have corrected in time.

The clip is the latest in a run of safety posts Tesla has amplified over the past several days. On Saturday, the company shared a video from Selling Sunset star Jason Oppenheim, who sold his Bentley for a Model Y and said he was buying Teslas with FSD for 10 of his employees. Ashok Elluswamy, who leads Tesla AI, followed up by writing that Tesla self-driving “reacts to other people cutting into your path with super-human response times.” On Monday, a Cybertruck owner posted footage of FSD moving across three lanes from a red light to clear a path for an ambulance approaching from behind.

This recent clip also lands a few weeks after Tesla began shipping Automatic Collision Evasion with FSD v14.3.9, a feature that can activate FSD on the driver’s behalf when a frontal collision is imminent or the driver appears distracted. Elluswamy said in September that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” are coming with v15, the release Tesla has tied to round the clock Robotaxi operation.

The safety messaging matters beyond social media. Tesla has said FSD Supervised was 4.1 times less likely to crash than manual driving across 100 million kilometers on European roads, and it has been putting those figures in front of regulators. Eight EU countries have now approved FSD Supervised, with Croatia the most recent, but the EU’s bloc-wide vote originally set for October 6 has been pushed to December at the earliest.

FSD Supervised is still a Level 2 system, and the driver remains responsible at all times. Even heavy users find reasons to step in. Teslarati’s Joey Klender, who uses FSD for about 76 percent of his driving, laid out five recurring issues on Tuesday that still prompt him to intervene. Clips like this one show the other column of that ledger: moments where the software caught a mistake a human was about to make.

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