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SpaceX’s backup Dragon launch pad on track for 2023 debut

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SpaceX has begun building a backup launch pad for its Cargo and Crew Dragon spacecraft and says the facility could be ready for use as early as fall 2023.

Reuters first revealed those plans in June 2022. They arose because NASA reportedly told SpaceX it was worried that the company’s first Florida Starship launch site – colocated at the only pad currently able to launch SpaceX Dragon spacecraft – could add too much risk. In September 2022, NASA and SpaceX acknowledged plans to modify LC-40 for Dragon launches and indicated that both parties had decided to proceed.

Four months later, SpaceX and NASA have provided another press conference update. Officials confirmed that construction is already partially underway and reported that LC-40 could be ready to support its first Dragon launch less than a year from now.

Because Boeing’s comparable Starliner capsule is years behind schedule and still unqualified to launch humans, NASA has relied almost exclusively on SpaceX’s Crew Dragon to launch its astronauts to the International Space Station (ISS) since 2020. Starliner should be ready to supplement Crew Dragon’s operational astronaut launches by the end of 2023 or early 2024, alleviating some of that pressure.

NASA, however, chose to develop two spacecraft to guarantee that one spacecraft would likely be available if the other was grounded for any reason. Adding the possibility that a giant, new, experimental rocket (Starship) could potentially halt all SpaceX Dragon launches in one fell swoop was apparently one bridge too many for the agency.

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LC-40 has supported 9 launches in the last 8 weeks. (Richard Angle)

SpaceX’s answer to the problem was about as simple, elegant, and cheap as possible. The company has two operational Falcon launch pads in Florida, and it proposed to modify the second pad. SpaceX’s Cape Canaveral Space Force Station (CCSFS) LC-40 pad is located on a secure military base and has an even longer history of successful Falcon 9 launches than Pad 39A. It also appears that its layout will allow SpaceX to add a Dragon access tower without requiring major redesigns or months of downtime.

LC-40 is SpaceX’s most productive launch pad by far, and the company intends to launch up to 100 times in 2023. It’s thus crucial that the pad remains as active as possible as it’s modified – a major challenge. A combination of luck and the fact that the launch pad is already operational is the only reason that’s possible.

Modifying SpaceX’s busiest pad

In theory, SpaceX needs to do relatively little to enable Dragon launches out of LC-40. Dragon spacecraft are processed for flight at a separate facility and only head to the pad once they’re ready to be attached to a Falcon 9 rocket. The biggest modification LC-40 needs is a launch tower, but SpaceX ironically has experience building giant towers in sections – and offsite – through Starship.

LC-40’s Dragon access tower requires far less complex plumbing and should be smaller and easier to prefabricate and assemble. Regulatory documents indicate that the new tower will stand 81 meters (265 feet) tall – almost a third shorter than the 110-meter-tall tower SpaceX modified at Pad 39A for the same purpose. LC-40 will also need a swinging access arm to connect the tower to Dragon’s hatch. That arm can also be constructed offsite, further reducing the amount of downtime required.

The top half of the LC-40 T/E visible here is clearly connected by removable bolts, likely making the process of modifying the pad to support Dragon launches much less disruptive than it could have been. (Richard Angle)

The most disruptive modifications may involve LC-40’s transporter/erector (T/E) device, which rolls Falcon 9 out to the pad, raises it vertical, holds it down with giant clamps; and hosts a maze of plumbing that fuels, pressurizes, and powers the rocket. The top of LC-40’s T/E is fitted with a brace designed to support Falcon payload fairings. In comparison, 39A’s T/E was designed with swappable ‘heads’ that allow SpaceX to switch between Dragon and fairing configurations in a matter of days. The top of LC-40’s T/E also appears to be somewhat removable, but SpaceX may still have to halt launches for a few weeks to get the T/E up to spec and modified for Dragon.

SpaceX says that LC-40 will be ready to support its first Dragon launch as early as fall (Q4) 2023. Its first Dragon mission will carry cargo to the ISS, meaning that the tower, arm, and pad will not need to be immediately human-rated. In theory, SpaceX could even launch Cargo Dragon 2 from LC-40 without a tower or arm, as the only purpose of the tower during uncrewed missions is to load volatile cargo at the last possible second. SpaceX could even revert to a practice that dates back to its original Dragon 1 spacecraft and devise a method to late-load cargo while Falcon 9 and Dragon are still horizontal.

Starship is nine times as heavy and almost twice as tall as Falcon 9. (SpaceX)

The tower and access arm are only essential for Crew Dragon launches, during which astronauts must board the spacecraft a few hours before liftoff. More importantly, the same arm and tower would be used to escape Dragon and Falcon 9 in case of a minor emergency. NASA requires an escape (egress) system to human-rate a launch pad and rocket. SpaceX met that requirement at Pad 39A with a “slidewire basket” system that carries astronauts to a concrete bunker several hundred feet away from the rocket. Before LC-40 can be human-rated, SpaceX will likely need to build the same basket-and-bunker system or come up with a viable alternative.

Once complete, SpaceX will have two pads capable of supporting all Crew and Cargo Dragon launches. With that redundancy in place, NASA should be far more open to regular launches of SpaceX’s next-generation Starship rocket out of Pad 39A. Access to multiple pads will likely be essential for Starship to complete NASA’s Human Landing System (HLS) contracts, which will culminate in the giant rocket sending humans back to the Moon for the first (and second) time in half a century in the mid-to-late-2020s.

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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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Samsung’s Tesla AI5/AI6 chip factory to start key equipment tests in March: report

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant.

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Image used with permission for Teslarati. (Credit: Tom Cross)

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant, which will produce Tesla’s next-generation AI5 chip. 

Preparing for Tesla’s AI5/AI6 chips

As per a report by Sina Finance, Samsung Electronics is looking to begin trial operations of extreme ultraviolet (EUV) lithography equipment at its Taylor facility in March. These efforts are reportedly intended to support the full production of Tesla’s AI5 chips starting in the latter half of 2026.

The Taylor factory, Samsung’s first wafer fabrication plant in the United States, covers roughly 4.85 million square meters and is nearing completion. Media reports, citing contractors, have estimated that about 7,000 workers now work on the factory, about 1,000 of whom are reportedly working from the facility’s office building. 

Samsung is reportedly preparing to apply for a temporary occupancy permit, which would allow production to begin before the plant is fully completed.

Tesla’s aggressive AI chip roadmap

Elon Musk recently stated that Tesla’s next-generation AI5 chip is nearly complete, while early development on its successor, AI6, is already underway. Musk shared the update in a post on X, which also happened to be a recruiting message for engineers.

As per Musk, Tesla is looking to iterate its in-house AI chips on an accelerated timeline, with future generations, including AI7, AI8, and AI9, targeting a roughly nine-month design cycle. He also stated that the rapid cadence could allow Tesla’s chips to become the highest-volume AI processors in the world.

Previous reports have indicated that Samsung Electronics would be manufacturing Tesla’s AI5 chip, alongside its rival, Taiwan Semiconductor Manufacturing Company (TSMC). The two suppliers are expected to produce different versions of Tesla’s AI5 chip, with TSMC using a 3nm process and Samsung targeting 2nm production.

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Elon Musk’s Boring Company studying potential Giga Nevada tunnel: report

The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

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(Credit: The Boring Company

Elon Musk’s tunneling startup, The Boring Company, has been studying a potential tunnel system connecting Reno to Tesla Gigafactory Nevada, as per documents obtained by Fortune. The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

Potential Giga Nevada tunnel

Documents reviewed by Fortune showed that The Boring Company received $50,000 in October to produce conceptual designs and a feasibility report for a tunnel beneath a nine-mile stretch of highway leading to Gigafactory Nevada. The payment came from the Economic Development Authority of Western Nevada (EDAWN), a nonprofit that works with the state to attract and expand businesses.

The proposed tunnel was one of several transportation alternatives being explored to address rising congestion and accidents along Interstate 80, which serves the Tahoe-Reno Industrial Center. The massive industrial park houses major employers, including Tesla and Panasonic, both of which had been in contact with the Nevada Governor’s Office regarding potential transportation solutions.

Emails obtained through public records requests showed that Tesla and Panasonic have also supported a separate commuter rail study that would use existing freight rail alongside the Interstate. It remains unclear if The Boring Company’s feasibility report had been completed, and key details for the potential project, including tunnel length, cost, and if autonomous Teslas would be used, were not disclosed.

The-boring-company-vegas-loop-chinatown
(Credit: The Boring Company)

Relieving I-80 congestion

Traffic and accidents along I-80 have increased sharply as data centers and new businesses moved into the 107,000-acre industrial center. State transportation data showed that the number of vehicles traveling certain stretches of the highway during peak hours doubled between January and July 2025 alone. Roughly 22,000 employees commute daily to the industrial park, with nearly 8,000 working for Tesla and more than 4,000 for Panasonic at the Giga Nevada complex.

Bill Thomas, who runs the Regional Transportation Commission of Washoe County, shared his thoughts about safety concerns in the area. “At this point in time, there’s about (one accident) every other day,” he said. He also noted that he is supportive of any projects that could alleviate traffic and accidents on the Interstate. 

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“We’re not paying for it. I’m not involved in it. But I understand there are conversations exploring whether that could be done. If there’s a private solution that helps the problem and improves safety, as far as I’m concerned, more power to them,” Thomas stated. 

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Tesla might have built redundancies for Cybercab charging

When Tesla unveiled the Cybercab in 2024, the company noted that the autonomous two-seater would utilize wireless charging.

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Credit: @AdanGuajardo/X

A newly spotted panel on Tesla’s Cybercab prototype may point to a practical backup for the vehicle’s wireless charging system as it nears mass production. 

Tesla watchers have speculated that the panel could house a physical NACS port, which would ensure that the autonomous two-seater could operate reliably even before the company’s wireless charging infrastructure is deployed.

Cybercab possible physical charge port

The discussion was sparked by a post on X by Tesla watcher Owen Sparks, who highlighted a rather interesting panel on the Cybercab’s rear. The panel, which seemed to be present in the prototype units that have been spotted across the United States recently, seemed large enough to house a physical charge port.

When Tesla unveiled the Cybercab in 2024, the company noted that the autonomous two-seater would utilize wireless charging. Since then, however, Tesla has remained largely quiet about the system’s rollout timeline. With the Cybercab expected to enter production in a few months, equipping the vehicle with a physical NACS port would allow it to charge at Superchargers nationwide without relying exclusively on still-undeployed wireless chargers.

Such an approach would not rule out wireless charging long-term. Instead, it would give Tesla flexibility, allowing the Cybercab to operate immediately at scale while wireless charging solutions are rolled out later. For a vehicle designed to operate continuously and autonomously, redundancy in charging options would be a practical move.

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Growing Cybercab sightings

Recent sightings of the Cybercab prototype in Chicago point to the same design philosophy. Images shared on social media showed the vehicle coated in road grime, while its rear camera area appeared noticeably cleaner, with visible traces of water on the trunk.

The observation suggests that the Cybercab is equipped with a rear camera washer. As noted by Model Y owner and industry watcher Sawyer Merritt, this is a feature Tesla owners have requested for years, particularly in snowy or wet climates where dirt and slush can obscure cameras and degrade the performance of systems like FSD.

While only the rear camera washer was clearly visible, the sighting raises the possibility that Tesla may equip additional exterior cameras with similar cleaning systems. For a vehicle that operates without a human driver,  after all, maintaining camera visibility in all conditions is essential. Ultimately, the charge-port speculation and camera-washer sightings suggest Tesla is approaching the Cybercab with practicality in mind.

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