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Investor's Corner

Tesla files to build EV batteries on new production lines at Fremont Factory

Credit: Tesla

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Tesla (NASDAQ: TSLA) has filed to build a new battery manufacturing equipment line at the Fremont Factory in Northern California. The factory, which Tesla purchased in 2010, is the only in the company’s lineup to produce all four models. It has not been known as a battery cell or pack manufacturing plant, as the company’s Gigafactory in Sparks, Nevada, produces those EV components. However, the filings indicate Tesla may be looking to slightly expand its cell manufacturing efforts with new production lines at Fremont.

Filed and signed by Tesla on August 30, the permit is labeled as “Tesla F21-0391-A – CTA Battery B-Build.” Tesla gives the following description of the project:

“NEW BATTERY MANUFACTURING EQUIPMENT LINE ON 2ND FLOOR OF MAIN ASSEMBLY BUILDING. THIS PERMIT APPLICATION RELATES TO THE MODULE PORTION OF THE LINE.”

The project is valued at $1.5 million, according to documents seen by Teslarati.

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tesla battery cell manufacturing filing

Credit: City of Fremont

Credit: City of Fremont

Additionally, another application reveals a $1.3 million project that includes the installation of a new maintenance office, a storage area, production cells with equipment for hood, fender, and trunk lids, and offline cell manufacturing equipment. This project is listed to be on the first floor of the assembly building.

Interestingly, the Fremont Factory has been one of Tesla’s more spacially-confined facilities. Earlier this year, during a visit from Morgan Stanley analysts, including Adam Jonas, the firm noted the Fremont Factory was incredibly tight in terms of storage capacity and room in general. Despite running at a capacity of 20 percent above what has been considered its maximum. “The plant was never designed to produce 450k units (at its peak produced ~300k units before Tesla took it over from Toyota), which was immediately apparent at the tour, ” Jonas wrote in his note describing the visit. “Tesla does not shy away from the fact the plant is inefficiently designed with four assembly buildings, one of which is a tent that cars are assembled in,” referring to GA 4.5, which was made permanent last year.

Just two weeks prior to Morgan Stanley’s visit to Fremont, CEO Elon Musk stated Tesla was considering expanding Fremont “significantly.” While many of us just thought this likely meant an expansion of vehicle production alone, Musk may have been hinting toward an expansion of the manufacturing process altogether.

Tesla battery manufacturing efforts

Tesla has held battery supply deals with Panasonic, CATL, and LG Chem, but has also started building its own cells in-house. In 2020, Tesla unveiled its 4680 battery cell, which has already been prototype-tested by Panasonic. Tesla has been building the cell at the Kato Rd. facility just a few blocks away from Fremont’s front doors. However, the automaker has not scaled this cell to mass production as of yet, and Tesla could always use more battery cells.

With the 4680 cell not quite reaching mass production volumes yet, an order log that grows with what seems to be every minute, and a production volume that just simply has not caught up to Tesla’s demand, it would make sense to expand in-house battery manufacturing efforts as supplementary support.

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“I think we’ve said this now for many years. I know has proven true. Tesla does not have a demand problem, we have a production problem. And we’ve almost always had it’s a very rare exception it’s always been a production problem,” Musk said after Q2. “I think that will remain the case.”

Rearranging at the Fremont Factory

Over the past month or so, Tesla has filed to make many significant changes at the Fremont Factory. After we reported on the construction efforts that are seemingly underway, Tesla has also been filing several applications with the City of Fremont for equipment repositioning, as well as the construction of new foundations and manufacturing equipment. Even things as simple as light poles are being repositioned to make way for potential new manufacturing buildings.

Tesla Fremont plant is abuzz with activity as nearby construction goes underway

Tesla has also started relocating Model S and X production equipment to other portions of the factory. “GASX,” which we can assume is “General Assembly Model S and X,” has had a hoist relocated, according to filings. Tesla has also filed to install production tools and other associated Model S and Model X manufacturing utilities in the factory. This does not necessarily imply that production lines for the two vehicles will be expanding, especially considering the vehicles make up an extremely small portion of Tesla’s overall sales. However, these manufacturing lines may be shifting to other locations at Fremont to make way for the perhaps imminent installation of cell manufacturing lines at Fremont.

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I’d love to hear from you! If you have any comments, concerns, or questions, please email me at joey@teslarati.com. You can also reach me on Twitter @KlenderJoey, or if you have news tips, you can email us at tips@teslarati.com.

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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SpaceX’s newest Starmind will make earth data centers obsolete

Elon Musk confirmed Starmind as SpaceX’s AI satellite constellation name, targeting one million orbital compute nodes.

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Elon Musk confirmed that Starmind will be the official name of SpaceX’s planned AI satellite constellation, following a trademark filing by xAI that surfaced earlier this week. Starmind is what’s being described to the FCC as a constellation of up to one million AI satellites

It’s worth noting that SpaceX’s Starlink communication satellite and Starmind are built on the same orbital infrastructure concept but serve entirely different purposes. Starlink is a connectivity network, with satellites receiving and relaying data between points on Earth, and functioning as a high-speed internet backbone in space. The satellites themselves do not process or think, and move information from one place to another, the same function a fiber cable performs underground.

SpaceX just forced Verizon, AT&T and T-Mobile to team up for the first time in history

Starmind, on the other hand, is something completely different, and tather than moving data, its satellites would compute data through artificial intelligence and directly in orbit using onboard processors powered by large solar arrays. Where a Starlink satellite is essentially a very fast pipe, a Starmind satellite is a server. The practical implication is that Starmind would allow AI models to run inference, process queries, and generate outputs from space, then beam results down to users anywhere on Earth within milliseconds, and without the data ever needing to travel to a terrestrial data center.

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Starship will be able to carry 30 to 50 AI1 satellites per launch, delivering the equivalent of dozens of server racks per flight, with no land acquisition, no power grid approval, and no cooling infrastructure required on the ground.

SpaceX is pursuing this new technology as terrestrial data centers are running into hard limits such as lack of physical space, community opposition, and power and water consumption at a scale that is increasingly difficult to permit. Space has unlimited solar power, natural vacuum cooling, and no zoning boards. Musk said in a June 8 video presentation that he expects space to become the lowest-cost location to deploy AI compute within two to three years. Two AI1 prototypes are scheduled to launch in early 2027, with volume production targeted for the end of that year at a new facility called Gigasat.

The real world applications Starmind enables extend well beyond powering Grok. A constellation of orbiting AI processors could run inference workloads for any paying customer, anywhere on Earth, with latency measured in milliseconds rather than the seconds associated with ground-based cloud routing across continents. Starmind, if it scales as described, would make SpaceX the landlord of AI compute the same way Starlink made it the landlord of satellite internet.

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Investor's Corner

SpaceX makes $20 billion move to optimize its balance sheet

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Credit: SpaceX

SpaceX announced today that it commenced its first-ever public bond offering, marking a significant step in the newly public company’s capital markets strategy.

The company announced an offering of senior unsecured notes expected to raise at least $20 billion.

The move comes just a short time after SpaceX completed one of the largest initial public offerings in history. In mid-June, the company priced shares at $135 and raised more than $85 billion, propelling founder Elon Musk’s net worth past the trillion-dollar mark and giving the firm substantial liquidity.

According to the company’s SEC filing, the net proceeds from the notes will be used primarily to repay in full the outstanding borrowings under its existing bridge loan facility, cover related fees and expenses, and fund general corporate purposes. The offering is being conducted under Rule 144A, as well as Regulation S, targeting qualified institutional buyers and non-U.S. investors. Notes will be unsecured obligations ranking equally with other unsubordinated debt.

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The $20 billion bridge loan was used to refinance approximately $17.5 billion in higher-cost “junk” debt tied to X and xAI. SpaceX had merged with xAI in February 2026 in an all-stock deal. The bridge facility, which matures in September 2027, had represented the bulk of SpaceX’s long-term debt.

SpaceX officially acquires xAI, merging rockets with AI expertise

In connection with the bond launch, SpaceX disclosed it held approximately $100.8 billion in cash and cash equivalents as of June 19. Investor calls began on the announcement date, with pricing and launch expected shortly thereafter. Rating agencies have assigned investment-grade ratings to the proposed bonds, reflecting confidence in SpaceX’s dominant position in commercial launches and the growth trajectory of its Starlink internet offering.

The debt raise also allows SpaceX to optimize its balance sheet by replacing short-term, higher-cost bridge financing with longer-date, lower-cost fixed-income securities. This provides greater financial flexibility to support capital-intensive initiatives, including the development of Starship, the expansion of the Starlink constellation, and the integration of AI capabilities following the xAI combination.

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SpaceX shares (NASDAQ: SPCX) fell sharply on the news, dropping over 16 percent overall on the market on Monday. The stock had surged initially after debuting but pulled back amid profit-taking and broader market dynamics.

Overall, the bond offering underscores SpaceX’s transition to a mature public company with access to diverse funding sources. It positions the firm to pursue its long-term vision of multiplanetary expansion and AI infrastructure, while maintaining a disciplined approach to its capital structure in a high-growth but capital-heavy industry.

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Investor's Corner

SpaceX is launching a secret spacecraft that could change how things are made in space

SpaceX’s secret disk-shaped Starfall capsule is targeting a market no reentry vehicle has cracked.

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SpaceX is targeting Tuesday, June 23 for the first flight of Starfall, a reentry capsule the company has developed almost entirely in private. The Falcon 9 launch window opens at 6:43 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available the same time on June 24. SpaceX has made no public announcement about the vehicle, only providing launch details. Everything known about it has come through FAA and FCC regulatory filings.

What makes Starfall different starts with its shape. Rather than the traditional cone used by Dragon and every other cargo return capsule in operation, Starfall is a flat disk that measures roughly  10.2 feet (3.1 meters) wide and just 2.5 feet (0.75 meters) tall, and weighing 4,630 pounds (2,100 kg) and capable of returning up to 2,200 pounds (1,000 kilograms) of payload from orbit. The disk geometry maximizes structural efficiency and payload volume relative to mass, and the heat shield mechanically jettisons just before splashdown, allowing recovery teams to retrieve both the capsule and the shield separately from the Pacific Ocean.

The difference with Starfall from existing competitors, such as Varda Space Industries, which has largely built the orbital manufacturing market and returns heavy payloads per flight is that Starfall’s specification is roughly 30 times more per mission, and is designed to be mass-produced and launched on either Falcon 9 or Starship. That combination of volume and launch access is something no standalone startup can replicate, and it puts SpaceX in direct competition with the companies that currently pay it to reach orbit.

SpaceX to launch military missile tracking satellites through new Space Force contract

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The intended market is orbital manufacturing: pharmaceuticals, protein crystals, semiconductors, and advanced optical fiber that physically cannot be produced in the presence of gravity. FAA documents describe Starfall’s long-term purpose as building a “self-sustaining commercial in-space manufacturing market” and as a potential successor to the industrial capabilities of the International Space Station, which is set to retire in the late 2020s. Military rapid global cargo delivery is a parallel application under active discussion with the Pentagon.

The reason some industries seek manufacturing in space comes down to gravity. On Earth, gravity causes materials to settle, separate, and deform during production. In microgravity, those constraints disappear.

SpaceX’s already controls launch access, which means it currently functions as the landlord for every competitor in the orbital manufacturing return space. Starfall converts that landlord position into vertical ownership, and it would no longer just carry other companies’ capsules to orbit, but rather operate the capsule, own the return logistics, and capture the service revenue directly. Viewed alongside Starlink, Colossus, and the xAI merger, Starfall fits a consistent pattern: SpaceX identifying infrastructure layers that others depend on and moving to own them outright. Orbital manufacturing return is the next layer on that list.

If Tuesday’s reentry, parachute sequence, and recovery demonstration goes as planned, the second FAA-approved test flight follows. A successful pair of demos would position SpaceX to begin offering Starfall as a commercial service, likely first to pharmaceutical and materials science customers before scaling toward the military and broader manufacturing segments.

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