Startup Besxar aims to build orbital semiconductor factory using SpaceX Falcon 9 boosters

Former OpenAI staffer Ashley Pilipiszyn raises $14M to prototype chip manufacturing in space

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A startup called Besxar is working with SpaceX to develop an orbital semiconductor factory, using the vacuum of space to produce cleaner materials for advanced chips. The company, founded by former OpenAI staffer Ashley Pilipiszyn, has raised nearly $14 million and successfully completed its first test flights aboard a Falcon 9 booster in July.

If you want to manufacture in space—and bring the products back again—there's a limited set of options: wait to go to the International Space Station, or partner with a handful of startups launching spacecraft that spend time in orbit before they return to Earth.

But the vehicle that goes to space and comes back to Earth more often than any other is a SpaceX Falcon 9 rocket booster, which made that round-trip 163 times last year and has already flown more than 100 times this year. Now, a startup says it has talked Elon Musk's space company into letting it prototype an orbital semiconductor factory across a dozen flights with the booster.

Besxar, a startup founded by former OpenAI staffer Ashley Pilipiszyn, wants to make the key precursors for advanced semiconductors by taking advantage of the vacuum of space. A key reason chip fabs on Earth are such hugely insane infrastructure projects is the need to create pressurized clean rooms to keep out even microscopic dust and contaminants that could ruin a chip during production. Pilipiszyn argues that a new generation of rockets could offer an alternative to all that infrastructure. To do it, she has raised almost $14 million, including a $9 million seed round led by Dauntless Ventures and Overture VC.

"We're at a time where it's actually more cost-effective to go where the physics already works," she told TechCrunch. "Don't do it on Earth where you're fighting physics."

The company's first two "fabships"—small canisters designed to carry and test semiconductor materials in orbit—flew on a July Starlink mission and were intended to prove that the canisters could survive a launch, protect wafer samples from contamination, and expose them to the vacuum of space. Besxar succeeded in these objectives despite a malfunction in the flight data system in one canister, which the company is currently investigating.

"The flown samples were the cleanest and had the least amount of particulate matter compared to … non-flown terrestrial wafers, which is fantastic for us as we scale up," Pilipiszyn told TechCrunch.

Besxar expects to keep iterating over the next two years, with the ultimate goal of flying larger fabs onboard a vehicle like SpaceX's Starship, the company's next-generation rocket still in development. Pilipiszyn first approached SpaceX three years ago to talk about buying flights on Starship and eventually settled on the booster payload deal as a way to de-risk her technology in the meantime. Next up is heating the wafers, then depositing one material on the wafers, then two materials, and so forth.

Once it is producing qualification samples, Besxar—named after "beskar," the metal used in Star Wars to make Mandalorian armor—wants to supply leading chipmakers with the wafers used to make the kinds of advanced chips that regulate electrical power in data centers, robots and electric vehicles.

There are a number of companies working to leverage the space environment for higher-quality semiconductors, including United Semiconductors and Space Forge, but all face the same difficulty: the limited ability to return a meaningful volume of product. Pilipiszyn expects to start to scale up to hundreds and then thousands of wafers per fab, but that path depends on cheap rockets. That in turn requires SpaceX to get Starship operational—or competitors like Rocket Lab and Stoke Space getting their own next-generation rockets off the ground.

"We believe that there is a solid transport layer now, so we can focus on the application layer," she told TechCrunch. "We can just focus on our core manufacturing and getting our products back down to earth to market as quickly as possible."

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Analysis

Why This Matters

  • Space-based semiconductor manufacturing could dramatically reduce the cost and complexity of chip fabrication by eliminating the need for ultra-clean rooms on Earth.
  • If successful, Besxar's approach could accelerate production of power-management chips critical for data centers, electric vehicles, and robotics.
  • The venture hinges on SpaceX's Starship becoming operational, making the timeline uncertain and tying the startup's fate to Musk's rocket development schedule.

Background

Semiconductor fabs are among the most expensive and complex industrial facilities ever built, often costing billions of dollars. Clean rooms must maintain extremely low levels of airborne particles, requiring massive air filtration systems and strict protocols. The vacuum of space offers a naturally contaminant-free environment, which advocates say could simplify chip manufacturing. Several companies are exploring orbital manufacturing, but getting products back to Earth in volume remains a major logistical challenge.

Key Perspectives

  • Besxar (Founder Ashley Pilipiszyn): The startup argues that the space environment is inherently cleaner and more cost-effective for certain semiconductor processes. It sees Falcon 9 boosters as a reliable, reusable platform for prototyping before scaling to Starship.
  • SpaceX: The company is providing payload space on its boosters, potentially gaining a new revenue stream and demonstrating a non-launch use case for its reusable rockets. Details of the commercial agreement have not been disclosed.
  • Skeptics/Observers: Return volumes remain a key hurdle—most orbital manufacturing projects to date have produced only small quantities. Scaling to hundreds or thousands of wafers per fab will require cheap, frequent access to space, which may be years away.

What to Watch

  • Progress on SpaceX's Starship development program—any delays or failures would directly affect Besxar's scaling plans.
  • Results from the company's upcoming flight tests as it adds heating and material deposition capabilities to its fabships.
  • Whether competitors such as Rocket Lab or Stoke Space can offer comparable reusable rocket services, creating alternatives to Starship.

Sources

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Zotpaper

Articles published under the Zotpaper byline are synthesized from multiple source publications by our AI editor and reviewed by our editorial process. Each story combines reporting from credible outlets to give readers a balanced, comprehensive view.