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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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SpaceX posts Starship booster feat that’s so nutty, it doesn’t even look real

The Super Heavy booster’s feat was so impressive that the whole maneuver almost looked like it was AI-generated.

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Credit: SpaceX/X

SpaceX has shared a video of a remarkable feat achieved by Starship’s Super Heavy booster during its 11th flight test.

The Super Heavy booster’s feat was so impressive that the whole maneuver, which was captured on video, almost looked like it was AI-generated.

Super Heavy’s picture perfect hover

As could be seen in the video shared by SpaceX, Starship’s Super Heavy booster, which is nearly 400 feet tall, smoothly returned to Earth and hovered above the Gulf of America for a few seconds before it went for its soft water landing. The booster’s picture-perfect maneuver before splashing down all but capped a near-flawless mission for Starship, which is about to enter its V3 era with Flight 12.

The booster’s balance and stability were so perfect that some users on X joked that the whole thing looked AI-generated. Considering the size of Super Heavy, as well as the fact that the booster was returning from space, the hovering display all but showed that SpaceX is dead serious about keeping its dominant lead in the spaceflight sector.

Starship V2’s curtain call

As noted in a Space.com report, Flight Test 11 achieved every major goal SpaceX had set for the mission, including deploying Starlink mass simulators, relighting Raptor engines in space, and executing a stable reentry for both the Starship Upper Stage and the Super Heavy booster. The feat also marked the second time a Super Heavy booster has been reflown, a milestone in SpaceX’s quest to make the entire Starship system fully reusable.

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Starship’s V2 vehicle will now give way to the upgraded Starship V3, which is designed for faster turnaround and higher payload capacity. The Starship program is expected to pursue even more aggressive targets in the coming months as well, with Elon Musk stating on social media platform X that SpaceX will attempt a tower catch for Starship Upper Stage as early as spring 2026.

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Elon Musk

Starship’s next chapter: SpaceX eyes tower catch after flawless Flight 11

Elon Musk has revealed the tentative timeframe for Starship’s next milestone that would push the spacecraft’s reusability to a whole new level. 

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Credit: SpaceX

Elon Musk has revealed the tentative timeframe for Starship’s next milestone that would push the spacecraft’s reusability to a whole new level. 

Following Flight 11’s flawless mission, Musk noted on X that SpaceX will be aiming to catch the Starship Upper Stage with its launch tower as early as spring 2026. This should pave the way for SpaceX to start optimizing Starship for maximum reusability.

Flight 11 closes the Starship V2 chapter on a high note

Starship’s eleventh flight, which launched from Starbase, Texas, achieved every major mission objective. The Super Heavy booster completed a successful ascent, hover, and soft splashdown in the Gulf of America, while the upper stage executed an orbit burn, deployed Starlink simulators, and returned with a controlled reentry over the Indian Ocean.

This mission officially closed the chapter on the second-generation Starship and first-generation Super Heavy booster, and it set the stage for a redesigned vehicle built for orbital payload missions, propellant transfer, and beyond. It should be noted that Elon Musk has mentioned on X that Starship V3, at least if things go well, might be capable of reaching Mars.

Elon Musk confirms tower catch attempt set for spring

After Flight 11’s success, Musk confirmed that SpaceX will attempt to catch the Starship Upper Stage with its launch tower arms, fondly dubbed by the spaceflight community as “chopsticks,” in the coming months. Musk’s announcement came as a response to an X user who asked when the tower could start catching the Starship Upper Stage. In his reply, Musk simply wrote “Springtime.” 

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Starship’s reusability is a key feature of the spacecraft, with SpaceX aiming to achieve a launch cadence that is almost comparable to conventional aircraft. For such a scenario to be feasible, launch tower catches of both Starship’s Upper Stage and its Super Heavy booster have to be routine.

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SpaceX is preparing to launch Starship V2 one final time

The mission will test reentry dynamics, new landing burn configurations, and heat-shield upgrades.

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Credit: SpaceX/X

SpaceX is preparing to launch its final Starship V2 rocket on October 13, 2025. The launch closes the curtain on Starship V2 and marks the start of the ambitious spacecraft’s V3 era. 

Liftoff for Flight 11 is scheduled for 7:15 p.m. ET from Starbase in South Texas, with a 75-minute launch window. The mission will test reentry dynamics, new landing burn configurations, and heat-shield upgrades ahead of the transition to the next-generation Starship V3.

Starship V3 and beyond

Elon Musk confirmed on X that Starship V3 is already in production and could be “built & tested” and perhaps even flown before the end of 2025. The new version is expected to feature major performance and scale improvements, with Musk stating that Starship V3, provided that things go well, might be capable of reaching Mars, though V4 is more likely to perform a full-scale mission to the red planet. 

“Only one more V2 left to launch,” Musk wrote back in August following Starship’s successful Flight 10 mission. In another post, Musk stated that “Starship V3 is a massive upgrade from the current V2 and should be through production and testing by end of year, with heavy flight activity next year.”

Starship V2’s final mission

Flight 11 is designed to push the limits of Starship V2. SpaceX engineers have intentionally removed heat-shield tiles in vulnerable areas to analyze how the vehicle handles atmospheric reentry under stress, as noted in a Space.com report. The test will also refine subsonic guidance algorithms and new landing burn sequences for the Super Heavy booster that would be used for Starship V3.

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“Super Heavy will ignite 13 engines at the start of the landing burn and then transition to a new configuration with five engines running for the divert phase. Previously done with three engines, the planned baseline for V3 Super Heavy will use five engines during the section of the burn responsible for fine-tuning the booster’s path, adding additional redundancy for spontaneous engine shutdowns. 

“The booster will then transition to its three center engines for the end of the landing burn, entering a full hover while still above the ocean surface, followed by shutdown and dropping into the Gulf of America,” SpaceX wrote in a post on its official website.

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