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SpaceX Starship factory eyes cutting-edge industry solutions for inspiration [updated]

SpaceX has assembled three upgraded Starship rings into what is believed to be the start of Starship prototype SN01. (NASASpaceflight - bocachicagal)

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Update: In a Twitter response to this article, SpaceX CEO Elon Musk says that the reality of things is unsurprisingly a bit more complex. As noted, the standards and requirements for aerospace hardware are much stricter than those needed for the water towers, storage tanks, and other utilities that existing commercial solutions are commonly used to build.

As such, it’s inaccurate to suggest that those off-the-shelf solutions are capable of building rockets right out of the box. Still, several pieces of commercial fabrication equipment from providers like IMCAR have been spotted in use at SpaceX’s Boca Chica, Texas Starship facilities. With “substantial capital and engineering” investments into making those solutions more precise, however, SpaceX may still be able to use existing hardware – or at least the concepts they underly – to rapidly build high-quality Starships and Super Heavy boosters.


A SpaceX engineer says that the company wants to adopt commercially-available manufacturing equipment that could allow its Boca Chica, Texas team to build Starship tank parts in minutes and nearly-complete rocket bodies in a matter of days.

Originally created to meet the needs of a variety of different companies – typically oil and gas related – that need efficient, affordable, and standardized storage tanks, a small but growing niche exists for semi-automated tank production. While there is some clear uncertainty given that the quality and consistency required for oil and gas needs or even simple water storage likely isn’t the same needed to meet strict spaceflight margins, SpaceX has already acquired several production tools from existing contractors and is working around the clock to prove that those same tools can be used to build large, reusable rockets.

The gamble is simple: if it turns out that off-the-shelf (COTS) equipment can become an almost turnkey solution for manufacturing high-quality Starship spacecraft and Super Heavy boosters, SpaceX may have found a shortcut to orbit, avoiding the huge expense of finding and building its own custom production solutions. But is that COTS tank fabrication hardware truly up to the task?

A sample of tank fabrication capable with off-the-shelf welding solutions from the likes of IMCAR.
(NASASpaceflight – bocachicagal)

At least right now, the simple answer is “yes”. Thanks to two highly successful destructive tests of Starship tank prototypes that wrapped up last month, SpaceX has confirmed that at least a subset of the available COTS solutions can be used to build Starships (theoretically) capable of orbital flight. To be clear, those tanks reached only the most basic kind of specification needed for a true orbital-class spacecraft, demonstrating that they can fairly easily survive the pressures required for Starship and its Super Heavy boosters to remain structurally sound from liftoff to touchdown.

SpaceX’s second Starship ‘test tank made it all the way to 8.5 bar (125 psi) before it burst, reportedly enough to safely launch astronauts on Starship. (NASASpaceflight – bocachicagal)

For the most part, the only truly COTS aspect of those test tanks were the flat, cylindrical rings at their center – produced by cutting and welding together giant sheets of coiled steel. The tanks’ domes were more or less welded together by hand with the help of large jigs, while finished domes and rings were also welded together by hand. Given that the welds used to create the rings themselves have never obviously been a problem, the success of Starship’s two test tanks can thus be heavily attributed to skilled welders’ hands rather than any particular off-the-shelf solution.

Still, the fact of the matter is that automatic solutions like those currently available exist for good reason – aside from requiring far less labor to produce similar results, the consistency and quality of those results can actually be much better than anything that can be reliably achieved in a more boutique fashion. This is, at least, the promise of solutions like those shown below.

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SpaceX certainly appears to be pursuing the best-case scenarios that could be made possible with some of the hardware shown above. Already, it looks like Starship ring segments – themselves formed and welded with semi-automated IMCAR hardware – are being stacked and tack welded (temporary welds used like clamps) inside one of SpaceX’s new tents before the stand holding those ring(s) rotates itself, automatically welding them together.

The three mated rings pictured above were assembled over the course of several days using some of those methods and COTS fabrication hardware. However, if SpaceX can refine its procedures – currently still in the oven, so to speak – and become an expert at modifying and using available tank fabrication hardware to fabricate rockets, the company could conceivably build entire Starship and Super Heavy bodies in a matter of days.

It might take a substantial amount of trial and error, but SpaceX is clearly well on its way.

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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 bolsters Referral Program with big change and bigger rewards

The Tesla Referral Program offers benefits to both car buyers and existing Tesla owners, including complimentary Full Self-Driving trials, free Supercharging miles, and discounts on select purchases, such as cars.

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Credit: Tesla

Tesla has bolstered its Referral Program by offering more significant benefits for both the referrer and the referee. However, it only applies to certain vehicles in the Tesla lineup.

The Tesla Referral Program offers benefits to both car buyers and existing Tesla owners, including complimentary Full Self-Driving trials, free Supercharging miles, and discounts on select purchases, such as cars.

It changes relatively frequently, and is a great way to encourage people to buy a new car. Tesla is routinely making adjustments to it to stimulate demand, but the referral program likely does not encourage too many sales. Instead, it’s more of a reward for the referrer.

However, the latest adjustments are more substantial for both the buyer and the owner, offering pretty sizeable discounts on the purchase price of a Model S, Model X, or Cybertruck.

There are also discounts for current owners, giving them money off of all five Tesla vehicles.

Here’s the rundown of the new Referral Program awards:

  • You’ll earn $250 in Tesla Credits for each person you refer who takes delivery of a new Tesla
  • The first 10 people who order a new Model S, Model X, or Cybertruck using your referral link and take delivery will receive $1,000 off their purchase
  • When you purchase a new Model S, Model X, or Cybertruck for yourself, you’ll get $1,000 off
  • When you purchase a new Model 3 or Model Y, you’ll get $500 off
  • Limited to 10 awards

This is a pretty big discount as $1,000 off a Model S, Model X, or Cybertruck is a nice benefit to three of Tesla’s most expensive vehicles.

The additional $500 off a Model 3 or Model Y is also a nice cushion. A similar Referral Program was launched by Tesla last August.

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Tesla adjusts ‘Actually Smart Summon’ to avoid one common complaint

Tesla is adjusting Summon Standby’s settings slightly to combat the loss of battery life some owners might see with the feature active.

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tesla summon
Credit: YouTube/Hector Perez

Tesla has adjusted one portion of its “Actually Smart Summon” (ASS) feature to address a common complaint from owners: battery drain.

Teslas have a lot of really awesome features that make them one of the most technologically advanced vehicle models on the market. Things like Sentry Mode, Cabin Overheat Protection, and ASS’s “Summon Standby” features all keep the car on its toes for anything that comes its way.

Tesla finally launches Actually Smart Summon and Dumb Summon

However, the activation of these features contributes to battery drain while the vehicle sits parked. The amount varies, but I personally have lost up to five percent with some of these features active. That’s a lot if you do not utilize home charging.

Tesla is doing what it can to combat the battery drain with each of these features. It has done so with Sentry Mode, as an update last year helped combat battery percentage loss due to the activation of the security feature.

Tesla is about to ship a fix to a big Sentry Mode issue

It also recently introduced “Low Power Mode,” which will automatically deactivate some features if your battery falls below 20 percent. This is a great way to combat battery loss if your car is parked somewhere long-term, like an airport, for example.

There is also another feature that is attached to ASS called “Summon Standby.” This keeps the vehicle awake in case the owner needs quick connectivity to the vehicle, allowing them to summon the car to their location swiftly.

But there’s a drawback: keeping this feature activated will drain the battery. By default, the feature is activated when you take your car home, so you have to turn it off manually by accessing the settings menu inside the vehicle.

Turning this off would save you between 2% and 3% overnight, in my experience. With ASS still being a feature that needs some work, I chose to turn Summon Standby off. ASS will still work with the standby mode deactivated; it will just take a few more seconds for your phone to connect to the vehicle.

Tesla is adjusting Summon Standby’s settings slightly to combat the loss of battery life some owners might see with the feature active.

According to Not a Tesla App, Tesla has rolled out two conditions for which Summon Standby will be deactivated automatically:

Overnight Deactivation

Summon Standby will automatically be deactivated from midnight to 6 a.m. every night, which appears to be a data-driven decision made by Tesla based on the feature’s least-used hours.

This automatic pause cannot be turned off, at least for the time being.

Extended Parking Deactivation

If your Tesla is parked for over 24 hours, Summon Standby will also be deactivated automatically.

This is a great way to save battery life for those who are on vacation or are at home for several days in a row. This works similarly to the Low-Power Mode we talked about earlier in this article.

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Neuralink is planning to launch US trials translating thoughts into text

The trial could help pave the way for people with speech impairments to communicate more quickly and efficiently.

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Credit: Neuralink

Neuralink, Elon Musk’s brain-computer interface company, is reportedly planning to start a US clinical trial in October to use its technology to translate thoughts directly into text. 

The trial was approved by the FDA under an investigational device exemption, and it could help pave the way for people with speech impairments to communicate more quickly and efficiently.

Thought-to-text technology

The upcoming trial aims to read speech directly from the brain, enabling participants to transmit words without moving their mouths or using a keyboard, as noted in a report from Bloomberg News.

DJ Seo, Neuralink’s president, told an audience at the Korea Foundation for Advanced Studies in Seoul that the company hopes to demonstrate communication with large language model AI platforms “at the speed of thought,” potentially faster than spoken speech.

“We think that it’s actually possible to demonstrate abilities to speak to the latest AI model, or LLM models, at the speed of thought, even faster than how you’re speaking, and being able to potentially get that information back through your AirPods, effectively closing the loop,” Seo stated.

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Production ambitions

Ultimately, Seo described the trial as a stepping stone toward broader human enhancement and consumer-facing applications, beyond the company’s initial focus on medical conditions like ALS, stroke, blindness, and Parkinson’s disease.

While initial implants will focus on patients with severe speech impairments, Neuralink plans to eventually expand to healthy individuals by 2030. The company aims to scale to 20,000 implants per year by 2031.

“We’re currently envisioning a world where, in about 3 to 4 years, there will be someone who’s otherwise healthy who’s going to get a Neuralink. If you’re imagining saying something, we would be able to pick that up,” the executive noted.

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