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SpaceX wins NASA funds to build and test Starship’s orbital refueling technology

SpaceX has won $3M from NASA to build and test the first full-scale Starship refueling nozzles. (SpaceX)

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On September 27th, NASA announced a new round of Tipping Point funding worth a total of $43.2M that will be dispersed among 14 separate companies, all focused on advancing “important technologies necessary for sustained exploration of the Moon and Mars.”

Aside from Blue Origin and a dozen others, SpaceX received $3M to work with NASA’s Marshall Space Flight Center (MSFC) to build and test “cryogenic fluid couplers”, a type of nozzle Starship will need to refuel in orbit.

Noted multiple times over the years (and in recent days) by both SpaceX and CEO Elon Musk, an extremely robust and reliable method of orbital refueling is essential to the success of Starship’s current designed – perhaps more so than any other single aspect of the next-generation launch vehicle. Although Starship-Super Heavy will likely offer respectable performance in single-launch mode, the implicit need to recover and reuse both booster and spacecraft takes a big chunk out of the rocket’s potential capabilities.

Starship needs a ton of extra hardware and propellant to enable recovery and reuse, critical to the spacecraft’s affordability. (SpaceX)

Much like Falcon 9 and Heavy must sacrifice performance for booster landings, Super Heavy will also need to retain some amount of propellant for its boostback and landing burns. However, while just 1 kg of orbital payload is lost for every ~5-10 kg of extra hardware and propellant on the booster, things are far more consequential when discussing orbital stage reusability. Every single kilogram of hardware and propellant meant for Starship recovery and reuse will result in a 1:1 reduction in payload capacity. This becomes highly consequential when recovering the spacecraft involves the addition of something like 100-200 metric tons worth of wings, fins, heat shield tiles, batteries, propellant, and more.

As such, SpaceX is faced with a conundrum: to make spaceflight truly cheap, full reusability is a necessity, but full reusability almost fundamentally constrains the resultant rocket’s performance and utility. SpaceX’s solution: prolific orbital refueling on the order of anywhere from 1-10+ dedicated tanker launches for every Starship launch. By refueling in Earth orbit, be it low Earth orbit or something much more eccentric, Starship can be extremely reusable while still offering performance that even a similarly-sized, fully-expendable rocket couldn’t begin to compete with.

Although the theory behind SpaceX’s strategy is undeniably sound, the fact remains that orbital refueling has never been tested anywhere close to the scale, speed, or reliability Starship will need for numerous in-orbit refuelings to be a practical solution. Assuming SpaceX uses every ounce of Starship and Super Heavy’s performance for each tanker launch to low Earth orbit (LEO), Starship will have to be able to repeatedly and rapidly transfer at least 150 metric tons (330,000 lb) of liquid oxygen and methane in microgravity conditions.

Two Starships meet in Earth orbit for a refueling mission. (SpaceX)

Without Earth’s gravity and the force of multiple Raptor engines to help things along, it could be quite a challenge to transfer hundreds of tons of propellant in a reasonable timeframe while in orbit. In fact, SpaceX already has Space Act Agreements in place with NASA centers to mature orbital propellant transfer technology. The September 27th award simply continues that relationship, although this particular case involves the first direct funding from NASA – meant to help SpaceX over the “tipping point”.

This time around, SpaceX will work directly with NASA MSFC to build and test actual prototypes of the nozzles (“cryogenic fluid couplers”) Starship will use to mate and refuel in orbit.

“SpaceX will collaborate with NASA’s Marshall Space Flight Center in Huntsville, Alabama, to develop and test coupler prototypes – or nozzles – for refueling spacecraft such as the company’s Starship vehicle. A cryogenic fluid coupler for large-scale in-space propellant transfer is an important technology to aid sustained exploration efforts on the Moon and Mars.”

NASA, 09/27/19

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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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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