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SpaceX Super Heavy tank prototype survives crush testing

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A tank prototype similar to SpaceX’s next-generation Super Heavy rocket booster has survived a series of tests that repeatedly attempted to destroy it.

Known as Booster 7.1 or B7.1, the tank is the latest in a long line of ‘test tanks’ designed to verify the performance of Starship and Super Heavy and qualify new designs and manufacturing techniques without risking an entire upper stage or booster. In general, that means that test tanks are as minimal as possible and much shorter than either Starship stage, but they’re also assembled out of nine-meter-wide (30 ft) steel barrels and domes almost identical to the sections that make up Starship and Super Heavy.

For most of the duration of SpaceX’s steel Starship program, ‘test tank’ work has followed a fairly consistent and linear development path, where tanks were used to verify design changes before those changes were implemented on more expensive prototypes. B7.1 firmly ignored that norm.

While it’s not an exact match, the tank – built out of two stacked rings and dome sections and measuring about 11 meters (~36 ft) tall – has a Super Heavy thrust structure (where Raptor engines would attach) and external stiffeners known as stringers that are (mostly) exclusive to Starship boosters.

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As its name suggests, B7.1 shares many of the significant design changes that SpaceX had already implemented on Super Heavy Booster 7 (B7). The company began testing B7 months before B7.1, subjecting the full-size booster to multiple cryogenic proof tests and Raptor thrust simulation testing to qualify its new thrust ‘puck’ and several other structural changes. SpaceX began testing B7.1 in late June, shortly before Super Heavy Booster 7 was damaged by an unplanned explosion that halted its first Raptor engine test campaign. B7.1 testing then restarted in mid-July and was completed by the end of the month.

For unknown reasons, SpaceX’s decision to build and test Booster 7 before B7.1 meant that any significant issues discovered during subsequent B7.1 testing could disqualify the booster for flight testing, potentially wasting the months of work and tens of millions of dollars already invested in the prototype. Ultimately, though, B7.1 appeared to sail through multiple cryogenic proofs and crush tests without any catastrophic issues. Only on the last crush test did any part of the test tank finally give way, and the resulting damage was minor.

B7.1 was not the first test tank to use the ‘can crusher’ setup, but it was the first to do so under cryo conditions. B2.1 is pictured on top. (NASASpaceflight – bocachicagal)

B7.1’s testing made use of a relatively new two-piece stand. The tank was first installed on a sturdy base using clamps similar to those on the Starbase orbital launch site’s (OLS) launch mount. Then, a hat-like structure was placed on top of the tank, resting on the surface that a Starship upper stage would sit on during launch. Massive ropes were finally dropped down to attach to hydraulic cylinders on the base. Once B7.1 was loaded with benign cryogenic liquid nitrogen (LN2), replicating most of the thermal and mechanical stresses of real oxygen/methane propellant, the hydraulic cylinders retracted, pulling the cap down to evenly exert massive crushing forces down the vertical axis of the test tank. Simultaneously, additional rams installed underneath B7.1 may have simulated the thrust of 13 central Raptor engines.

It’s unclear what exactly SpaceX was testing. The goal of the test could have been as simple as verifying that Super Heavy Booster 7 can withstand the weight of a fully-fueled Starship (~1350 tons / ~3M lb) sitting on top of it. It could have also been used to simulate an entire orbital launch from Super Heavy’s perspective, replicating many of the forces Starship boosters will experience between liftoff and landing. Given that Booster 7’s upgraded thrust puck had already made it through stress testing, B7.1 didn’t have much to add there, but it may have been useful for estimating the compressive strength of the current Super Heavy booster design.

Regardless of what B7.1 did or didn’t prove, it did so with very little drama. After four long days of testing, at least two of which involved attempting to crush the tank, the only truly noteworthy visual event was evidence of a slight buckle near the top of the tank during its last crush test. A few days later, with the test stand ‘cap’ removed, B7.1 survived one final test in which SpaceX likely attempted to pressurize the tank until it burst. Instead, the tank didn’t so much as develop a leak, reiterating – contrary to their occasional tin-can-like appearances – just how sturdy Starship and Super Heavy really are.

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A small, bent edge at the top of B7.1 is the only evidence that SpaceX repeatedly tried to destroy the tank. (NASASpaceflight – bocachicagal)

With nothing more to give, SpaceX will likely scrap B7.1. Meanwhile, Super Heavy Booster 7 remains stuck inside one of SpaceX’s Starbase assembly bays after being forced back to the factory by unintentionally explosive testing. The fate of that booster is unclear but SpaceX has removed all or most of its 33 Raptor engines over the last few weeks while simultaneously expediting work on Booster 8, which may ultimately take B7’s place.

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 teases crazy outlook for xAI against its competitors

Musk’s response was vintage hyperbole, designed to rally supporters and dismiss doubters, something his responses on social media often do.

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Credit: NVIDIA

Elon Musk has never been one to shy away from crazy timelines, massive expectations, and outrageous outlooks. However, his recent plans for xAI and where he believes it will end up compared to its competitors are sure to stimulate conversation.

In a bold and characteristic response on X, Elon Musk fired back at a recent analysis that positioned his AI venture, xAI, as lagging behind industry frontrunners.

The post, from March 14, came as a direct reply to forecaster Peter Wildeford’s assessment, which drew from benchmarks and reporting to rank AI developers.

Wildeford placed Anthropic, Google, and OpenAI in a virtual tie at the top, with xAI and Meta trailing by about seven months. Chinese players like Moonshot, Deepseek, zAI, and Alibaba were estimated to be nine months behind, while France’s Mistral lagged by about a year and a half.

Musk’s response was vintage hyperbole, designed to rally supporters and dismiss doubters, something his responses on social media often do.

He claimed xAI would “catch up this year,” meaning by the end of 2026, erasing that seven-month deficit against the leaders. But he didn’t stop there.

Musk escalated his vision to 2029, predicting xAI would “exceed them all by such a long distance” that observers would need the James Webb Space Telescope, NASA’s orbiting observatory stationed about 930,000 miles from Earth, to spot whoever lands in second place. This analogy underscores Musk’s confidence in xAI’s trajectory, implying an astronomical lead that could redefine the AI landscape.

Breaking down these claims reveals Musk’s strategic optimism. First, the short-term catch-up: xAI, launched in 2023, has already released models like Grok, but recent benchmarks, including those for Grok 4.2, have shown it falling short in capabilities compared to rivals.

Anthropic’s Claude series, Google’s Gemini, and OpenAI’s GPT models dominate in areas like reasoning, coding, and multimodal tasks. Musk’s assertion suggests aggressive scaling in compute, talent, or architecture, perhaps leveraging xAI’s ties to Tesla’s Dojo supercomputers or Musk’s vast resources, to close the gap swiftly.

The longer-term dominance by 2029 paints an even more audacious picture. Musk envisions xAI not just parity but supremacy, outpacing competitors in innovation speed and model sophistication.

This could involve breakthroughs in energy-efficient training, real-world integration, like Tesla’s robotics, or ethical AI alignment, aligning with Musk’s stated goal of “understanding the universe.”

Critics, however, point to parallels with Tesla’s Full Self-Driving delays; one reply highlighted Musk’s 2023 promise of FSD readiness. Musk has made this promise for many years, and although the system has been strong and improving, it is still a ways off from the completely autonomous operation that was expected by now.

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Musk’s comment highlights the intensifying U.S.-centric AI race, with xAI challenging the “three-way” dominance noted by Wharton professor Ethan Mollick, whom Wildeford quoted. As geopolitical tensions rise—evident in the Chinese firms’ lag—Musk’s tease could spur investment and talent wars.

Yet, it also invites scrutiny: Will xAI deliver, or is this another telescope-needed mirage? In an industry where timelines slip but stakes soar, Musk’s words keep the spotlight on xAI’s ambitious path forward.

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Tesla Terafab set for launch: Inside the $20B AI chip factory that will reshape the auto industry

Tesla set to launch “Terafab Project: A vertically integrated chip fabrication effort combining logic processing, memory, and advanced packaging.

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Tesla is making one of the boldest bets in its history. On March 14, Elon Musk posted on X that the “Terafab Project launches in 7 days,” pointing to March 21, 2026 as the start date for what he has described as a vertically integrated chip fabrication effort combining logic processing, memory, and advanced packaging.

Tesla first confirmed Terafab on its January 28, 2026 earnings call, where Musk told investors the company needs to build a chip fabrication facility to avoid a supply constraint projected to materialize within three to four years. But the seeds were planted even earlier. At Tesla’s annual general meeting last year, Musk warned that even in the best-case scenario for chip production from their suppliers, it still wouldn’t be enough, and declared that building a “gigantic chip fab” simply had to be done.

While there has been no official announcement on where Tesla plans to break ground on the massive Terafab, all signs point to the North Campus of Giga Texas in Austin.

Months of speculation has surrounded Tesla’s North Campus expansion at Giga Texas, where drone footage captured by observer Joe Tegtmeyer revealed massive construction site preparation just north of the existing factory on a scale that rivals the original Giga Texas footprint itself.

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The project is projected to produce 100–200 billion AI and memory chips annually, targeting 100,000 wafer starts per month, at an estimated cost of $20 billion. Tesla is targeting 2-nanometre process technology and anticipated to be the most advanced node currently in commercial production. Dubbed the Tesla AI5 chip, the chip will pack 40x–50x more compute performance and 9x more memory than AI4, and will be among the first products Terafab factory is set to produce. This highly optimized, and massively powerful inference chip is designed to make full self-driving (FSD) and Tesla’s Optimus robots faster, safer, and with full autonomy.

tesla-optimus-pilot-production-line

(Credit: Tesla)

This is where Terafab becomes a genuine game-changer. If Tesla successfully builds a 2nm chip fab at scale, it becomes one of only a handful of entities that’s capable of producing AI silicon in-house, with competitive implications that extend far beyond Tesla’s own vehicles, and potentially positioning Tesla as a chip supplier or licensor to other industries.

The next-gen Tesla AI chips will power advancements in Full Self-Driving software, the Cybercab Robotaxi program, and the Optimus humanoid robot line. Musk’s projections for Optimus require chip volumes that no existing external supplier can commit to on Tesla’s timeline.Competitors like Waymo and GM’s Cruise remain dependent on third-party silicon, leaving them exposed to the same supply chain vulnerabilities Tesla is now working to eliminate entirely.

The Terafab launch this week may not mean a factory opens its doors overnight, but it signals Tesla is serious about owning the entire AI stack, from software to silicon.

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What is Digital Optimus? The new Tesla and xAI project explained

At its core, Digital Optimus operates through a dual-process architecture inspired by human cognition.

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Credit: Grok

Tesla and xAI announced their groundbreaking joint project, Digital Optimus, also nicknamed “Macrohard” in a humorous jab at Microsoft, earlier this week.

This software-based AI agent is designed to automate complex office workflows by observing and replicating human interactions with computers. As the first major outcome of Tesla’s $2 billion investment in xAI, it represents a powerful fusion of hardware efficiency and advanced reasoning.

Tesla announces massive investment into xAI

At its core, Digital Optimus operates through a dual-process architecture inspired by human cognition.

Tesla’s specialized AI acts as “System 1”—the fast, instinctive executor—processing the past five seconds of real-time computer screen video along with keyboard and mouse actions to perform immediate tasks.

xAI’s Grok model serves as “System 2,” the strategic “master conductor” or navigator, providing high-level reasoning, world understanding, and directional oversight, much like an advanced turn-by-turn navigation system.

When combined, the two can create a powerful AI-based assistant that can complete everything from accounting work to HR tasks.

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The system runs primarily on Tesla’s low-cost AI4 inference chip, minimizing expensive Nvidia resources from xAI for competitive, real-time performance.

Elon Musk described it as “the only real-time smart AI system” capable, in principle, of emulating the functions of entire companies, handling everything from accounting and HR to repetitive digital operations.

Timelines point to swift deployment. Announced just days ago, Musk expects Digital Optimus to be ready for user experience within about six months, targeting rollout around September 2026.

It will integrate into all AI4-equipped Tesla vehicles, enabling parked cars to handle office work during downtime. Millions of dedicated units are also planned for deployment at Supercharger stations, tapping into roughly 7 gigawatts of available power.

Digital Optimus directly supports Tesla’s broader autonomy strategy. It leverages the same end-to-end neural networks, computer vision, and real-time decision-making tech that power Full Self-Driving (FSD) software and the physical Optimus humanoid robot.

By repurposing idle vehicle compute and extending AI4 hardware beyond driving, the project scales Tesla’s autonomy ecosystem from roads to digital workspaces.

As a virtual counterpart to physical Optimus, it divides labor: software agents manage screen-based tasks while humanoid robots tackle physical ones, accelerating Tesla’s vision of general-purpose AI for productivity, Robotaxi fleets, and beyond.

In essence, Digital Optimus bridges Tesla’s vehicle and robotics autonomy with enterprise-scale AI, promising massive efficiency gains. No other company currently matches its real-time capabilities on such accessible hardware.

It really could be one of the most crucial developments Tesla and xAI begin to integrate, as it could revolutionize how people work and travel.

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