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SpaceX borrows Tesla's tent factory strategy for new Starship production HQ

SpaceX is rapidly building a giant tent almost identical to Tesla's tented assembly line to build Starships in South Texas. (NASASpaceflight - bocachicagal)

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Confirmed yesterday morning by CEO Elon Musk, SpaceX has copied Tesla’s approach to factory expansion and is building a giant tent to upgrade its South Texas Starship production facilities.

A big step towards more traditional aerospace-style manufacturing facilities, SpaceX has contracted the same company used by Tesla to create a fourth general assembly line (GA4) in a giant tent outside its Fremont, CA factory in 2018. Instead of Model 3s, however, Sprung Instant Structures (Sprung for short) is rapidly raising a large tent that will eventually allow SpaceX to fabricate and weld more Starship parts and sections in an enclosed environment, an improvement from the current practice of building prototypes out in the harsh environment of coastal Texas.

In typical fashion, Musk believes that the new enclosed production facilities – just a collection of shipping crates as of December 18th – could be ready to begin manufacturing Starship parts as early as next month, and the progress Sprung has made makes it unusually hard to fault his optimism.

Likely taken in mid-December, aerial photos taken by pilot and photographer Sam Sun help sketch out a rough view of the prospective Starship factory. SpaceX appears to have almost entirely foregone a concrete foundation for the new tent, instead opting for lines of steel shipping containers that likely add a bit of height at the cost of structural stability.

According to figures printed right on one of Sprung Structures’ many shipments of materials, the initial building will measure approximately 45 meters (150 ft) wide, 77 meters (255 ft) long, and 18 meters (60 ft) tall. While Tesla’s GA4 tent is the same width and (mostly) height, it’s an impressive 280 meters (915 ft) long – almost four times bigger than SpaceX’s newest Boca Chica addition.

While the shipping container foundation is definitely a bit of a risk a mile from the Gulf of Mexico, it does mean that SpaceX might actually be able to move the shell of its new Starship factory if the need arises. SpaceX is in the midst of expanding its Boca Chica lots, potentially giving the company a lot more space to grow its enclosed factory down the road. The simplest possible expansion available would basically double the length of the existing structure, making it more like 150-180 meters (500-600 ft) long.

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December 20th, 2019. (NASASpaceflight – bocachicagal)
In classic Sprung Structure fashion, the company has almost completely finished the shell of the new Starship factory in perhaps two weeks, pictured here on December 30th. (NASASpaceflight – bocachicagal)

Regardless, even the current 150′ x 255′ enclosure will end up offering more than 38,000 ft² (3500 m²) of factory space once finished. Depending on what its primary purpose is, SpaceX could probably fit 5-8 stacks of 5-6 rings each (10-11m tall) down the center of the tent, with room for maybe 10-24 additional stacks of 2-3+ rings (3.5-5m tall) in the space remaining. The middle line of hypothetical rings could produce the entire barrel section of 1-2 Starships simultaneously, leaving perhaps 3-4 large sections to be welded together out in the elements or at SpaceX’s new wedge-shaped windbreak.

Of course, the facility will likely end up being mixed-use, potentially offering enough space to simultaneous fabricate all subsections of a single Starship prototype before they are assembled elsewhere.

Ultimately, Sprung is now in the process of installing a large quantity of insulation inside the tent’s walls, indicating that SpaceX’s South Texas welding crew may soon be blessed with a climate-controlled work environment. Meanwhile, SpaceX CEO Elon Musk believes that Boca Chica’s new tent could be complete and ready to begin building Starship hardware as soon as January 2020, while he says that the next Starship prototype – now known as Starship SN01 (serial number 01) – could be ready for flight testing just one or two months after that.

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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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Elon Musk

Elon Musk spotlights the Starlink rescue that got through where no cell tower could

Elon Musk spotlighted how Starlink helped rescuers reach five people stranded in Kazakhstan’s snowy mountains.

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Elon Musk put a spotlight on a mountain rescue in eastern Kazakhstan on Sunday, writing “Starlink saves lives” in response to a post describing how SpaceX’s satellite internet helped five stranded people reach emergency crews.

The post from DogeDesigner, which had been viewed more than 500,000 times by Sunday afternoon, said the group’s SUV broke down about 15 kilometers from the village of Kystau Kurchum in an area with no usable mobile network. Starlink carried their call for help and kept them in contact with rescuers, who used the connection to locate them.

The rescue itself took place in October. Local outlet YK.kz reported on October 22 that Kazakhstan’s Ministry of Emergency Situations responded to the breakdown in the Kurchum district of East Kazakhstan region and noted that the group stayed in touch through Starlink. Rescuers covered roughly 100 kilometers in a Trekol, a low pressure tire vehicle built for snow and marshland, then escorted the disabled SUV back to Kystau Kurchum. Nobody needed medical attention.


Conditions in the region were rough at the time. Kazakh broadcaster Channel 7 identified the five as hunters caught in a snow trap and said satellite communication allowed rescuers to pinpoint where they were. A spokesperson for the East Kazakhstan emergency department said a storm warning was in effect and urged residents not to leave populated areas unless necessary. The same weather stranded seven utility workers repairing power lines in the nearby Kuygan rural district, according to Tengrinews.

Kazakhstan has been one of Starlink’s more notable markets in Central Asia. Teslarati reported in 2024 that Starlink was serving 1,731 of the country’s 1,879 schools, with the country’s Education Minister saying it had set a new standard for internet service in schools.

Rescue stories like this one have followed Starlink for years, usually in places where ground networks fail or never existed in the first place. Then Florida CFO Jimmy Patronis called Starlink a “game changer” for search and rescue crews during Hurricane Milton, and SpaceX and T-Mobile switched on Starlink Direct to Cell in North Carolina to push emergency alerts to phones after Hurricane Helene.

The next target is dead zones for people who do not carry a dish at all. SpaceX is building out Starlink Mobile and earlier this week selected Qualcomm to supply core infrastructure for a planned terrestrial 5G network in the United States, which it intends to pair with its next generation satellite constellation.

Sunday’s post is at least the third time Musk has written “Starlink saves lives” on X this week, following identical posts on November 5 and November 7.

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SpaceX will perform Starship double catch attempt with Flight 15

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Credit: SpaceX

SpaceX plans to attempt what will be a defining moment in rocket reusability on Starship Flight 15.

As Elon Musk announced in a recent X post, SpaceX will attempt to catch both the Super Heavy Booster and the Starship upper stage during the upcoming orbital flight. If successful, it will mark the first time that all parts of an orbital rocket return to Earth intact, a breakthrough Musk has called essential to making life multiplanetary.

Previous flights have demonstrated the tower-catch technique with Super Heavy. SpaceX has successfully caught V1 boosters three times (on Flights 5, 7, and 8), with some even reflown. The Ship upper stage has never been caught.

Returning from orbital velocity after deploying payload makes it a significantly harder challenge due to higher energy, heat loads, and the need for precise belly-flop reentry, a flip maneuver, and a final landing burn to settle between the Mechazilla tower’s chopstick arms.

Flight 15, using Booster 22 and Ship 42 (both Block 3 vehicles), is targeted for no earlier than Friday, November 13, 2026, from Orbital Launch Pad 2 at Starbase, Texas. The 75-minute window opens at 4:45 p.m. CT, pending regulatory approval. After hot staging and separation, the booster is planned to return for a catch roughly 6 minutes and 35 seconds after liftoff.

The Ship will insert into a roughly 275 km orbit, deploy 26 advanced Starlink V3 satellites, complete about 14 orbits over more than 22 hours, and—if systems check out—perform a deorbit burn, reentry, flip, and landing burn for a tower catch at approximately T+22 hours 32 minutes.

SpaceX confirms Starship 15 launch window with massive ambitions

A simulation shown during SpaceX’s October earnings call depicted the Ship descending in a belly-flop attitude, flipping upright with a short engine burn, and being captured by the arms:

Contingency splashdown zones exist in the Gulf of Mexico (booster) and Pacific (Ship) if a catch is not viable. SpaceX has stressed rigorous health checks before committing the Ship to a return-to-launch-site trajectory.

Musk has described the odds of success on this first dual-catch attempt as “more likely than not,” noting a steady stream of additional flights is already scheduled if needed. Full recovery would enable rapid inspection, refurbishment, and reflight—slashing costs and supporting the high launch cadence required for Starlink expansion, lunar missions, and eventual Mars settlement.

As Musk put it, this is “the critical breakthrough needed to make life multiplanetary.”

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Tesla Cybercab is set to get some massive improvements

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Credit: TechOperator | X

Tesla Cybercab is going to get some pretty substantial updates, including improvements to efficiency and a new color.

CEO Elon Musk said in a post on X on Saturday that Tesla would be working to refine the Cybercab even more, following the announcement during the week that the company would eliminate the Cybertruck lines within Giga Texas for more Cybercab manufacturing capacity.

“There are efficiency improvements coming that will allow for a 40kWh Cybercab pack,” Musk posted on X. “We will make this in liquid silver, so the colors are not too monotonous.”

A new, more efficient model of the Cybercab will be engineered, which will only help Tesla’s profitability and margins, and it also boosts the argument for why the Cybertruck should be discontinued, at least from a business perspective.

The current Cybercab that operates in the Robotaxi platform in Austin, Texas, has a 48 kWh pack, and it sounds like Musk believes Tesla is on its way to introducing a version that has fewer cells but can manage the same workload thanks to engineering efficiencies.

Credit: Tesla

Musk also doubled down on the decision to prioritize Cybercab production over Cybertruck, which is a decision that has been extremely polarizing within the community, and many fans have made it abundantly clear that they are not particularly pleased with the plans.

“If we have to maintain a complex production line, supply chain, and allocate engineering for Cybertruck, we can’t use those people or factory space and machinery for scaling Cybercab, which is the vehicle that will PROFOUNDLY transform the world of terrestrial transport,” Musk said.

Cybercab is obviously Tesla’s path forward in an automotive sense. It seems that Tesla is less concerned about catering to the passenger vehicle market and is more prone to focus on transforming passenger transportation in a way that prioritizes autonomy. However, this requires some sacrifice on Tesla’s end, and the Cybertruck is unfortunately a victim of this.

Cybercab holds an extremely crucial part of Tesla’s future. With the company already revolutionizing passenger transportation once, this is the next phase, and Cybercab is the path forward.

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