Inside Elon Musk’s plan to build one Starship a week—and settle Mars

BOCA CHICA BEACH, Texas—How badly does Elon Musk want to get to Mars? Let me tell you a story. On Sunday, February 23, Musk called an all-hands meeting at the South Texas site where SpaceX is building his Starship spacecraft.

It was 1am.

At an hour when most Americans were throwing down their last shots before closing time, at home in bed, or binge-watching The Office before it leaves Netflix, Musk brought his team together. He wanted to know why the Starship factory wasn’t humming at all hours. Why steel sheets weren’t getting welded into domes and fuel tanks, why tanks were not being stacked into rockets, why things weren’t going as fast as he wanted.

Musk always wants to go fast. He will not live forever, and the money may eventually run dry. He knows this. One day, the window to spread humanity to Mars may close, but Musk doesn’t know when. So he needs to squeeze through before the window shuts.

To really accelerate, his bleary-eyed engineers and technicians responded, they needed enough employees to assign workers to particular stations within the burgeoning factory, allowing each person to specialize. This would require a lot more hands that could build things.

“I said, ‘OK no problem,’” Musk recalls. “I said, ‘You can hire people—just know your reputation is on the line. Don’t bring your brother-in-law who can’t ever get a job. Not that person, OK? You’re going to be responsible for them. Everyone’s got their relatives that they know at the family gathering who, man, I sure as hell wouldn’t want to work with that person. Don’t bring that person. Bring the person who you’d put your reputation on the line for.’”

SpaceX had held a much publicized “career day” in early February, and the company hired several dozen new employees. By contrast, this Starship factory’s scale-up would be all word of mouth. And it would happen immediately.

Musk told his team members they would have a recruitment gathering just 12 hours later, at 1pm that Sunday. They would have another one on Monday at 1pm and then again at 8pm. Long lines of people showed up, family members and friends, mostly local. Cars and trucks jammed the roadside up and down Boca Chica Highway. At 11pm on Monday night, SpaceX was still hiring.

All told, the company added 252 people to its South Texas Launch Site on that Sunday and Monday. It doubled the workforce, just like that, to more than 500 workers. Most of the new hires, even those who had inked contracts at midnight, were told to report for work the next morning. A year ago, perhaps a dozen or so people worked on site. Soon, the Texas factory will probably be SpaceX’s largest location outside of its headquarters in Hawthorne, California.

Elon Musk will spend money to go fast, and in South Texas he is proving it. In a matter of weeks, SpaceX has built a small city down here, hard by the Rio Grande River. It is all rather astonishing. And maybe, just maybe, this new Muskville really will serve as a launch pad to the first city on Mars.

Meet the chief engineer

This past weekend, following the hiring spree, I visited the company’s facilities at Musk’s invitation. My tour included a visit to the launch pad. You may have seen the video footage of a Starship prototype known as Serial Number 1 (SN1) blowing apart during a pressurization test. This happened the night before my arrival. Engineers had loaded liquid nitrogen into the vehicle’s fuel tanks to determine their ability to hold very cold liquids at high pressure. The answer: not very well.

Bent, blackened, and charred, steel wreckage was strewn about the site. At first glance, it looked bad. But upon closer inspection, not all seemed lost. The launch tower for the vehicle appeared largely undamaged. The ground systems and fuel tanks that support Starship on the pad were located behind a berm and bore only a few scars from rocket shrapnel.

SN1 was never destined to fly, anyway. The plan for this vehicle, had it survived the pressurization test, was to install a Raptor engine and perform a static test firing. If everything looked just right on this test, Musk might have greenlighted a test with three Raptor engines. But probably not. The attitude of engineers working on the program boiled down to this: it sucks to lose SN1, but the next vehicle in line is already outpacing it. SN2 will soon be ready for tank testing.

Not that Musk felt particularly happy about losing a Starship. On Saturday and Sunday, he huddled with his engineers inside the University of Texas’ Stargate building, at the periphery of the company’s South Texas footprint. A year ago, the few rooms SpaceX leased on the building’s second floor were the only facilities on site aside from a few construction trailers. Now it is merely the front door. SpaceX has taken over the entire building, turning it into a mix of offices and storage.

On Sunday afternoon, I met Musk inside a Stargate conference room where he sat at a long table, wearing an “Occupy Mars” T-shirt and drinking a Diet Coke.

“Well, I just had a lot of talks with the team about that today,” he said of the SN1 failure. “It’s what you might call the thrust puck—there’s an inverted cone where we mount the three sea-level engines. In fact, it’s drawn on that whiteboard over there.”

He walked up to the whiteboard and pointed to a frowning face. “This is my drawing,” he said with a smirk. Then, with a dry-erase marker in hand, Musk proceeded to lecture about rockets.

“There’s a sad face because we have an inverted cone,” he said. “It’s such a dumb design. It’s one of the dumbest things on the whole rocket because it’s heavy, expensive, and unreliable.”

Basically, the SN1 failure boiled down to bad welds in a weak section of Starship near the engine. When exposed to pressure, the welds burst.

Musk was not happy because he had not heard about this specific issue, in this section of Starship, before the test failure. Do you think Musk addressed that with his team? Yeah, he addressed that.

“We sent out a note to the team that this was badly designed, badly built, and badly checked,” he said. “That’s just a statement of fact. I met with the whole quality team, and I said, ‘Did you think that that thing was good?’ They said, ‘No.’ I told them that, in the future, you treat that rocket like it’s your baby, and you do not send it to the test site unless you think your baby’s going to be OK. They said that they did raise the concern to one of the engineers. But that engineer didn’t do anything. ‘OK,’ I said, ‘then you need to email me directly.’ Now they understand. If you email me directly, and if I buy off on the risk, then it’s OK. What’s not OK is they think that the weld is not good, they don’t tell me, they take it to the pad and blow it up. Now I have been clear. There’s plenty of forgiveness if you pass me the buck. There is no forgiveness if you don’t.”

What you need to understand about Musk is that he is the chief engineer of SpaceX—and that’s not a courtesy title. Musk previously told me that at the very beginning of SpaceX, no great engineers would take the job, and what’s the point of hiring someone to be chief engineer who isn’t great? So he became the chief engineer of SpaceX. Almost every technical rocket decision made at SpaceX comes to him eventually. Especially the hard ones. He has spent many, if not the majority, of his days since December in South Texas. During Christmas, employees there say, he worked all-nighters alongside them to get the dome structure and the welds right for SN1.

Yet Musk has not been spending so much of his time in South Texas just to build a Starship. Rather, he’s trying to build a production line for Starships. He wants to build a lot of them. And fast, always fast.

“Production is at least 1,000 percent harder than making one of something,” he said. “At least 1,000 percent harder.”

Musk should know. He lived through “production hell” at Tesla in 2017 and 2018, building up factories, changing processes, spending many sleepless nights and going through all manner of mental agony. Now, Tesla is making as many as 10,000 cars a week.

He wants to implement a similar system in South Texas. Musk, in fact, aims to reach a point where the company builds a Starship a week by the end of this year. And after that? Maybe they’ll go faster. SpaceX is designing its factory here to build a Starship every 72 hours.