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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.

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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.

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 and Tesla AI Director share insights after empty driver seat Robotaxi rides

The executives’ unoccupied tests hint at the rapid progress of Tesla’s unsupervised Robotaxi efforts.

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Ashok Elluswamy

Tesla CEO Elon Musk and AI Director Ashok Elluswamy celebrated Christmas Eve by sharing personal experiences with Robotaxi vehicles that had no safety monitor or occupant in the driver’s seat. Musk described the system’s “perfect driving” around Austin, while Elluswamy posted video from the back seat, calling it “an amazing experience.”

The executives’ unoccupied tests hint at the rapid progress of Tesla’s unsupervised Robotaxi efforts.

Elon and Ashok’s firsthand Robotaxi insights

Prior to Musk and the Tesla AI Director’s posts, sightings of unmanned Teslas navigating public roads were widely shared on social media. One such vehicle was spotted in Austin, Texas, which Elon Musk acknowleged by stating that “Testing is underway with no occupants in the car.” 

Based on his Christmas Eve post, Musk seemed to have tested an unmanned Tesla himself. “A Tesla with no safety monitor in the car and me sitting in the passenger seat took me all around Austin on Sunday with perfect driving,” Musk wrote in his post.

Elluswamy responded with a 2-minute video showing himself in the rear of an unmanned Tesla. The video featured the vehicle’s empty front seats, as well as its smooth handling through real-world traffic. He captioned his video with the words, “It’s an amazing experience!”

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Towards Unsupervised operations

During an xAI Hackathon earlier this month, Elon Musk mentioned that Tesla owed be removing Safety Monitors from its Robotaxis in Austin in just three weeks. “Unsupervised is pretty much solved at this point. So there will be Tesla Robotaxis operating in Austin with no one in them. Not even anyone in the passenger seat in about three weeks,” he said. Musk echoed similar estimates at the 2025 Annual Shareholder Meeting and the Q3 2025 earnings call.

Considering the insights that were posted Musk and Elluswamy, it does appear that Tesla is working hard towards operating its Robotaxis with no safety monitors. This is quite impressive considering that the service was launched just earlier this year.

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Starlink passes 9 million active customers just weeks after hitting 8 million

The milestone highlights the accelerating growth of Starlink, which has now been adding over 20,000 new users per day.

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Credit: Starlink/X

SpaceX’s Starlink satellite internet service has continued its rapid global expansion, surpassing 9 million active customers just weeks after crossing the 8 million mark. 

The milestone highlights the accelerating growth of Starlink, which has now been adding over 20,000 new users per day.

9 million customers

In a post on X, SpaceX stated that Starlink now serves over 9 million active users across 155 countries, territories, and markets. The company reached 8 million customers in early November, meaning it added roughly 1 million subscribers in under seven weeks, or about 21,275 new users on average per day. 

“Starlink is connecting more than 9M active customers with high-speed internet across 155 countries, territories, and many other markets,” Starlink wrote in a post on its official X account. SpaceX President Gwynne Shotwell also celebrated the milestone on X. “A huge thank you to all of our customers and congrats to the Starlink team for such an incredible product,” she wrote. 

That growth rate reflects both rising demand for broadband in underserved regions and Starlink’s expanding satellite constellation, which now includes more than 9,000 low-Earth-orbit satellites designed to deliver high-speed, low-latency internet worldwide.

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Starlink’s momentum

Starlink’s momentum has been building up. SpaceX reported 4.6 million Starlink customers in December 2024, followed by 7 million by August 2025, and 8 million customers in November. Independent data also suggests Starlink usage is rising sharply, with Cloudflare reporting that global web traffic from Starlink users more than doubled in 2025, as noted in an Insider report.

Starlink’s momentum is increasingly tied to SpaceX’s broader financial outlook. Elon Musk has said the satellite network is “by far” the company’s largest revenue driver, and reports suggest SpaceX may be positioning itself for an initial public offering as soon as next year, with valuations estimated as high as $1.5 trillion. Musk has also suggested in the past that Starlink could have its own IPO in the future. 

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NVIDIA Director of Robotics: Tesla FSD v14 is the first AI to pass the “Physical Turing Test”

After testing FSD v14, Fan stated that his experience with FSD felt magical at first, but it soon started to feel like a routine.

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Credit: Grok Imagine

NVIDIA Director of Robotics Jim Fan has praised Tesla’s Full Self-Driving (Supervised) v14 as the first AI to pass what he described as a “Physical Turing Test.”

After testing FSD v14, Fan stated that his experience with FSD felt magical at first, but it soon started to feel like a routine. And just like smartphones today, removing it now would “actively hurt.”

Jim Fan’s hands-on FSD v14 impressions

Fan, a leading researcher in embodied AI who is currently solving Physical AI at NVIDIA and spearheading the company’s Project GR00T initiative, noted that he actually was late to the Tesla game. He was, however, one of the first to try out FSD v14

“I was very late to own a Tesla but among the earliest to try out FSD v14. It’s perhaps the first time I experience an AI that passes the Physical Turing Test: after a long day at work, you press a button, lay back, and couldn’t tell if a neural net or a human drove you home,” Fan wrote in a post on X. 

Fan added: “Despite knowing exactly how robot learning works, I still find it magical watching the steering wheel turn by itself. First it feels surreal, next it becomes routine. Then, like the smartphone, taking it away actively hurts. This is how humanity gets rewired and glued to god-like technologies.”

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The Physical Turing Test

The original Turing Test was conceived by Alan Turing in 1950, and it was aimed at determining if a machine could exhibit behavior that is equivalent to or indistinguishable from a human. By focusing on text-based conversations, the original Turing Test set a high bar for natural language processing and machine learning. 

This test has been passed by today’s large language models. However, the capability to converse in a humanlike manner is a completely different challenge from performing real-world problem-solving or physical interactions. Thus, Fan introduced the Physical Turing Test, which challenges AI systems to demonstrate intelligence through physical actions.

Based on Fan’s comments, Tesla has demonstrated these intelligent physical actions with FSD v14. Elon Musk agreed with the NVIDIA executive, stating in a post on X that with FSD v14, “you can sense the sentience maturing.” Musk also praised Tesla AI, calling it the best “real-world AI” today.

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