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3D-printed Mars habitat could be a perfect fit for early SpaceX Starship colonies

A glimpse of AI SpaceFactory's MARSHA Mars habitat. (AI SpaceFactory & PLOMP)

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Space architecture startup AI SpaceFactory achieved second place in the latest phase of a NASA-led competition, pitting several groups against each other in pursuit of designing a 3D-printed Mars habitat and physically demonstrating some of the technologies needed to build them.

With a focus on ease of scalable 3D-printing and inhabitants’ quality of life, as well as the use of modular imported goods like windows and airlocks, MARSHA lends itself impeccably well to SpaceX’s goal of developing a sustainable human presence on Mars as quickly, safely, and affordably as possible with the support of its Starship/Super Heavy launch vehicle.

Aside from developing a custom 3D-printing material utilizing in-situ Martian resources and demonstrating the technology by successfully printing a 1200 gallon (4500 L) water tank, SpaceFactory’s habitat design – known as MARSHA – combines a unique level of pragmatism, functionality, and aesthetic elegance. After analyzing different structural options, the SpaceFactory team settled on a cocoon-like cylinder, taking advantage of the many benefits of the Martian environment while controlling for its several downsides. Most notably, Martian gravity is roughly 38% of Earth’s, while the small planet’s atmosphere is typically 80-150 times less dense at surface-level. As a consequence, the forces exerted by Martian winds are minuscule and can effectively be ignored, while the low gravity dramatically minimizes architectural challenges that arise from Earthbound structures having to battle their own weight.

Equally important, all Martian habitats will need to be pressurized to a level comfortable for long-term colonists, requiring that they be able to survive significant internal pressurization. The Martian radiation environment is also significantly less forgiving than Earth, although the dangers of Martian radiation are dramatically overblown. The material of choice SpaceFactory designed to 3D-print its MARSHA habitat – a biorenewable plastic (PLA) reinforced with locally-sourced basalt fiber – also accounts for many of Mars’ shortcomings, as plastics happen to be some of the best materials for radiation shielding per unit of mass. Featuring a duo of PLA shells placing a meter or more of plastic between living areas, MARSHA would permit relatively acceptable radiation levels while avoiding the downsides of locating habitats underground or burying them under several meters of Martian regolith.

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Thanks to its cylindrical design and SpaceFactory’s attention to quality of life for astronauts residing within it, MARSHA is also exceptionally beautiful and more than a little alluring even from the perspective of Earthly habitation. MARSHA’s thoughtful design and polished aesthetic would likely mesh well with SpaceX CEO Elon Musk’s own established preferences, known (sometimes infamously so) for a predilection towards building things that value form at least as much as function. Due to the relatively compact nature of the hardware needed (in theory) to begin building MARSHA and the apparent potential for autonomous construction, SpaceFactory’s design also aligns with a number of critical aspects of SpaceX’s outlined Mars colonization architecture.

 

Up next for NASA’s 3D-printed habitat competition is “Phase 3”, effectively a grand finale: up to eight finalists are expected to compete to 3D-print a 1/3rd scale model of their Mars habitat design as early as May 2019. While not confirmed, it’s likely that SpaceFactory will be among those finalists, potentially helping to offer an early glimpse at what rapidly-printed Mars habitats might look like in real life. SpaceX CEO Elon Musk has also indicated that he would provide a more substantial update on the status of BFR (Starship/Super Heavy) and SpaceX’s Mars architecture soon after the company’s first Starship prototype – unofficially known as Starhopper – begins test flights. That milestone is like no fewer than 1-2 months away.


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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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Elon Musk

SpaceX’s next project will produce Starships at a level that sounds impossible

1,000 rockets per year is an insane number, especially considering Starship’s sheer size.

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Credit: SpaceX

Elon Musk has revealed bold plans for SpaceX’s newest Starbase facility in Texas, predicting it will become a birthplace for “so many spaceships.” The upcoming “Gigabay,” a massive $250 million production hub in Starbase, Texas, is designed to manufacture up to 1,000 Starship rockets per year.

That’s an insane number of rockets for a single facility, especially considering Starship’s sheer size. 

One of the world’s largest industrial structures

SpaceX’s Gigabay is expected to stand roughly 380 feet tall and enclose 46.5 million cubic feet of interior space, making it one of the largest industrial structures to date. The facility will feature 24 dedicated work cells for assembling and refurbishing Starship and Super Heavy vehicles, complete with heavy-duty cranes capable of lifting up to 400 U.S. tons, as noted in a Times of India report.

Construction crews have already placed four tower cranes on-site, with completion targeted for December 2026. Once operational, the Gigabay is expected to boost SpaceX’s launch cadence dramatically, as it would be able to build up to 1,000 reusable Starships per year, as noted in a report from the Dallas Express. Musk stated that the Gigabay will be “one of the biggest structures in the world” and hinted that it represents a major leap in Starbase’s evolution from test site to full-scale production hub.

A key step toward Mars and beyond

Starship is SpaceX’s heavy-lift rocket system, and it remains a key part of Elon Musk’s vision of a multiplanetary future. The vehicle can carry 100–150 tonnes to low Earth orbit and up to 250 tonnes in expendable mode. With several successful flights to date, including a perfect 11th test flight, the Starship program continues to refine its reusable launch system ahead of crewed lunar missions under NASA’s Artemis initiative.

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Starship is unlike any other spacecraft that has been produced in the past. As per Elon Musk, Starship is a “planet-colonizer” class rocket, as the magnitude of such a task “makes other space transport task trivial.” Considering Starship’s capabilities, it could indeed become the spacecraft that makes a Moon or Mars base feasible. 

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Cybertruck

Tesla Cybertruck fleet takes over at SpaceX’s Starbase

Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.

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Credit: @derek1ee | X

Tesla Cybertrucks have taken over at SpaceX’s Starbase facility in Texas, as hundreds of the all-electric pickup trucks were spotted late last week rounding out a massive fleet of vehicles.

The Cybertruck fleet is geared toward replacing gas vehicles that are used at Starbase for everyday operations. The only surprise about this is that it was not done sooner:

Deliveries have been going on for a few weeks, as Cybertrucks have made their way across the state of Texas from Austin to Starbase so they could be included in SpaceX’s fleet of vehicles at the facility.

Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.

However, there are some other perspectives to consider as SpaceX is utilizing such a massive fleet of Cybertrucks. Some media outlets (unsurprisingly) are seeing this as a move of weakness by both Tesla and SpaceX, as the aerospace company is, in a sense, “bailing out” lagging sales for the all-electric pickup.

It’s no secret that Tesla has struggled with the Cybertruck this year, and deliveries have been underwhelming in the sense that the company was anticipating between 1 million and 2 million orders for the vehicle before it was widely produced.

A lot of things changed with the Cybertruck between its 2019 unveiling and 2023 initial deliveries, most notably, price.

The price of the Cybertruck swelled significantly and priced out many of those who had pre-ordered it. Some have weighed the option of whether this purchase was a way to get rid of sitting inventory.

However, it seems more logical to consider the fact that SpaceX was likely always going to transition to Teslas for its fleet, especially at Starship, at some point.

It doesn’t seem out of the question that one Musk company would utilize another Musk company’s products, especially considering the Cybertruck has been teased as the vehicle that would be present on Mars.

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News

SpaceX successfully launches 100th Starlink mission of 2025

With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.

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(Credit: Starlink)

SpaceX achieved its 100th Starlink mission of the year on Friday, October 31, marking another milestone for 2025. 

A Falcon 9 rocket carrying 28 Starlink broadband satellites successfully lifted off from Vandenberg Space Force Base in California at 4:41 p.m. ET, carrying another 28 Starlink satellites to Low Earth Orbit (LEO).

Falcon 9 booster’s 29th flight

Roughly 8.5 minutes after liftoff, the Falcon 9’s first stage touched down on the drone ship Of Course I Still Love You in the Pacific Ocean. This marked the booster’s 29th flight, which is approaching SpaceX’s reuse record of 31 missions.

This latest mission adds to SpaceX’s impressive 138 Falcon 9 launches in 2025, 99 of which were dedicated to Starlink, according to Space.com. The company’s focus on reusing boosters has enabled this breakneck pace, with multiple launches each week supporting both Starlink’s expansion and external customers.

Starlink’s network continues massive global expansion

Starlink remains the largest active satellite constellation in history, with more than 10,000 satellites launched, nearly 8,800 of which are currently active. SpaceX recently achieved Starlink’s 10,000-satellite milestone. With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.

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Starlink, which provides high-speed, low-latency internet connectivity even to the world’s most remote areas, has been proven to be life-changing technology for people across the globe. The service is currently operational in about 150 countries, and it currently has over 5 million subscribers worldwide. From this number, 2.7 million joined over the past year.

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