SpaceX has returned an upgraded Super Heavy booster to the factory after an unexpected explosion and fireball caused “minor” damage during testing.
CEO Elon Musk first revealed that the company would need to remove the rocket from Starbase’s orbital launch pad for inspections and repairs on July 13th, about a day and a half after the anomaly. On July 11th, during what may have been a partial wet dress rehearsal (WDR), a dispersed cloud of methane gas found an accidental ignition source and exploded with a force that at least one observer estimated was equivalent to several pounds of TNT. Several nail-biting hours of uncertainty followed, during which SpaceX attempted to empty Super Heavy Booster 7 of its propellant (and explosive potential) and regain control of the situation, while simultaneously trying to avoid stoking a fire that started at the pad.
With a heaping serving of luck, Booster 7 made it through the event (mostly) intact. Now SpaceX must take a close appraisal of the rocket and situation and decide how to proceed.
Musk, as always, has put his optimistic face forward on Twitter and in a direct response to Reuters. According to an email sent shortly after an early in-person post-anomaly inspection, Musk stated that Booster 7 could return “to the launch stand probably next week” – implying that any damage suffered was extremely minor. By the time Super Heavy was removed from the launch mount the next day (July 14th), however, it became clear that the situation wasn’t quite as optimal.
Instead, Booster 7’s aft engine section was clearly damaged, with some of the dozens of thermal protection panels enclosing 33 Raptor engines apparently torn off or knocked askew by the July 11th blast. Given the tight fit and relatively heavy-duty nature of some of those panels, deformation could easily damage some of the more sensitive plumbing and components on Raptor engines. The day prior, teams spent hours tearing out unexpectedly fragile components of Booster 7’s hidden aft heat shielding and even removed and replaced one of its Raptors in-situ.
More likely than not, all Raptor engines with minor damage can be repaired and reused on a future booster. The explosion may also give SpaceX invaluable data that can be used to improve the durability and performance of Raptor and Super Heavy’s heat shield. Nonetheless, a methodical inspection of Booster 7’s aft end could easily take a week or two. If more chronic damage is discovered or the whole aft heat shield or a large number of Raptors need to be removed and replaced, the hiatus could grow to a month or more.
Following Booster 7’s July 15th return to the Starbase factory, SpaceX appears to have begun removing more Raptor engines on July 17th, kicking off a phase that will hopefully be heavy on encouraging inspection results and light on substantial repairs. If it turns out that the Super Heavy prototype is mostly in great shape after such a violent anomaly, it would bode well for the rocket’s durability during future ground and flight testing. If it did not fare well, SpaceX may need to seriously reconsider whether Booster 7 is fit to support Starship’s orbital launch debut or even proceed into static fire testing.
Either way, SpaceX recently finished stacking Super Heavy Booster 8. If it’s made a priority, the newest prototype could be made ready to take over where Booster 7 left off within a few weeks. Alternatively, it could even join a repaired Booster 7 at the launch pad for basic proof testing while its predecessor attempts to restart its first static fire campaign. Simultaneously, Starship S24 is almost ready to begin its own static fire test campaign, guaranteeing an eventful and hardware-rich period at Starbase after several months of relative inaction.
SpaceX has 12-hour road closures likely meant for Ship 24 testing scheduled daily from Monday, July 18th to Thursday, July 21st.
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SpaceX just locked up a NASA record no other U.S. spacecraft can touch
SpaceX’s Crew-13 Dragon reached the ISS in under eight hours, and NASA confirmed a record.
SpaceX now owns every spot on the list of the five fastest trips a U.S. spacecraft has ever made to the International Space Station, and its newest entry beat the old mark by more than four hours.
Crew Dragon Grace docked to the forward port of the station’s Harmony module at 7:05 p.m. ET on October 1, just 7 hours and 55 minutes after lifting off from Space Launch Complex 40 at Cape Canaveral. NASA confirmed the milestone in a space station blog update, writing that the flight “marked the fastest launch‑to‑docking of a U.S. spacecraft in the history of the International Space Station.”
The previous U.S. record also belonged to Dragon. SpaceX’s uncrewed CRS-31 cargo mission reached the station in a little over 12 hours in November 2024. The fastest crewed trip before last week was Crew-11, which took 14 hours and 43 minutes in August 2025, according to Space.com.
A post that Elon Musk reposted on Monday filled out the rest of the ranking. Behind Crew-13, CRS-31 and Crew-11 sit Axiom’s Ax-2 mission at 15 hours and 35 minutes and NASA’s Crew-4 at 15 hours and 44 minutes. All five flew on Dragon.
SpaceX turned a heralding moment for Starship into its greatest
Crew-13 carried NASA astronauts Jessica Watkins and Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and Roscosmos cosmonaut Sergey Teteryatnikov. NASA had projected a docking around 8 p.m. ET, as Teslarati reported the day before launch, and Dragon arrived nearly an hour early. Our launch day coverage noted that the flight was lined up to be the quickest Crew Dragon transit yet.
The speed came from timing more than hardware. SpaceX’s Julianna Scheiman said the station “was in an opportune spot in space,” which let Dragon start closing the gap almost immediately after reaching orbit. “This is close to the fastest it could be,” she added. Most Crew Dragon flights still take close to a day, using a series of Draco thruster burns to raise and phase their orbit before arrival.
Dragon’s next job at the station is a departure. NASA said Monday it is targeting 8:05 a.m. ET on Wednesday, October 7, for Crew-12 to undock, setting up a splashdown off the coast of California around 11:34 a.m. on Thursday. Clearing that port makes room for CRS-35, a cargo Dragon carrying the final set of iROSA solar arrays.
Dragon remains NASA’s only operational ride to the station while Boeing’s Starliner stays grounded, and the agency recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification.
Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
SpaceX just locked up a NASA record no other U.S. spacecraft can touch
Elon Musk teases TSMC as potential Terafab partner
