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The Boring Company’s unveiling showed another Musk-driven disruption in the making

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Before the opening party for the Hawthorne test tunnel began, Elon Musk gave a rather straightforward presentation about The Boring Company’s technology to members of the media. The discussion provided a number of pertinent updates and new information about the tunneling startup’s activities, several of which were reiterated when Musk took the stage to open the unveiling event.

As the Tesla and SpaceX CEO lightheartedly discussed the updated concepts of The Boring Company’s tunneling technology, it quickly became evident that Tuesday’s event could very well be the start of yet another Elon Musk-driven disruption.

Every single company that Elon Musk started, or played a part in starting, has gone on to be a disruptor of an established industry. In his 20s, Musk and his brother Kimbal shook up the widely established Yellow Pages industry with Zip2. Musk later took on traditional banking with X.com, which eventually merged with PayPal, one of the internet’s most established financial services that are still widely used today. Tesla, an electric car startup Musk backed in its very early days, is now an automaker forcing legacy carmakers to design and release compelling EVs. SpaceX, a company that could be considered as the culmination of Musk’s childhood dreams of interplanetary travel, is becoming more and more prevalent in the US space industry.

In a way, Musk’s penchant for disruption results from his tendency to look at problems and adopt unconventional strategies to arrive at breakthrough results. In the case of SpaceX, for example, it was the company’s capability to reuse rockets that is allowing it to compete in the space industry. Electric vehicles existed before Tesla too, but the company made itself different by creating EVs that were desirable in both design and performance. This same thinking was evident when Musk presented his ideas for The Boring Company. The startup didn’t necessarily reinvent the wheel when it came to tunneling, but the company did employ a number of novel solutions that allowed it to make tunneling a lot faster, for a far lower price.

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At the core of The Boring Company’s concepts are its smaller tunnel designs, which feature roughly half the diameter of conventional tunnels. This, according to the startup, reduces costs by 3-4 times. The Boring Company is also aiming to develop ways to increase the speed of its Tunnel Boring Machines (TBMs). Traditional TBMs are notable for their slow speed, and Elon Musk has lightly noted that a snail is effectively 14 times faster than a boring machine. As such, the Boring Co. aims to develop TBMs that can actually keep pace with a snail. The Hawthorne test tunnel provides a glimpse of the cost savings associated with the company’s tunnel design as well, as the 1.14-mile project was completed with just $10 million of funding. Musk notes that conventional tunneling projects, which use larger tunnels and slower machines, can balloon to up to $1 billion per mile. 

Musk has mentioned that The Boring Company has been working on improving the capabilities of its TBMs. For its next-gen machine, Musk stated that the tunneling startup had developed a new TBM cutter head that operates faster, allowing it to process and move dirt in a more efficient manner. The Tesla and SpaceX CEO further noted that The Boring Company is developing a system that will enable reinforcement segments to be created and set up on site. The company is even planning on using the dirt from the cutter head as material for tunnel reinforcements. Such a system would allow the tunneling startup to increase its digging speeds even further, especially considering that conventional tunneling practices usually involve only 10% of actual digging, with 90% of operations usually being consumed by the laying of tunnel reinforcements.

Being a company started by Elon Musk, The Boring Company is in a constant state of innovation. This was evident in the updates to the electric skates design that were initially planned for the Loop system. Concepts of the high-speed tunnels involved vehicles traveling on electric skates. On Tuesday, though, Musk noted that “There won’t be a skate. The vehicle is the skate.” Such a system was adopted in the Hawthorne tunnel’s test rides, where a Model X fitted with electric skates on its front wheels was used to transport passengers through the tunnel. Even the garage-elevator that would be used to lift vehicles back onto the road is created with efficiency in mind, being pre-fabricated and constructed off-site. 

A Tesla Model X being lifted through a vehicle elevator. (Credit: The Boring Company)

Just like his other ventures, The Boring Company has the potential to be a disruptor. With its ultra-high-speed tunnels, the startup might actually help solve the problem of traffic congestion. The Boring Company’s tunnels could even be a stepping stone towards the eventual creation of Hyperloop transportation, which involves pods traveling inside low-pressure tubes at speeds of up to 700 mph. The Boring Company’s disruption might not only be limited to transportation, either, as the startup is also poised to release the Boring Bricks, which are blocks made from tunneling rock that could be used for low-cost housing. Permits for the creation of The Brick Store, a physical outlet where these blocks are set to be sold, have also been.

The Boring Company might be a fun startup, complete with Not-a-Flamethrowers, pet snails, sharp-tongued French knights, and a Monty Python-style watchtower made of Boring Bricks, but beneath all the unveiling event’s fun atmosphere was the sense that there is another disruption in the making — one that could complement the innovations being pushed by SpaceX and Tesla.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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