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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.


Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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 spotlights the Starlink rescue that got through where no cell tower could

Elon Musk spotlighted how Starlink helped rescuers reach five people stranded in Kazakhstan’s snowy mountains.

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Elon Musk put a spotlight on a mountain rescue in eastern Kazakhstan on Sunday, writing “Starlink saves lives” in response to a post describing how SpaceX’s satellite internet helped five stranded people reach emergency crews.

The post from DogeDesigner, which had been viewed more than 500,000 times by Sunday afternoon, said the group’s SUV broke down about 15 kilometers from the village of Kystau Kurchum in an area with no usable mobile network. Starlink carried their call for help and kept them in contact with rescuers, who used the connection to locate them.

The rescue itself took place in October. Local outlet YK.kz reported on October 22 that Kazakhstan’s Ministry of Emergency Situations responded to the breakdown in the Kurchum district of East Kazakhstan region and noted that the group stayed in touch through Starlink. Rescuers covered roughly 100 kilometers in a Trekol, a low pressure tire vehicle built for snow and marshland, then escorted the disabled SUV back to Kystau Kurchum. Nobody needed medical attention.


Conditions in the region were rough at the time. Kazakh broadcaster Channel 7 identified the five as hunters caught in a snow trap and said satellite communication allowed rescuers to pinpoint where they were. A spokesperson for the East Kazakhstan emergency department said a storm warning was in effect and urged residents not to leave populated areas unless necessary. The same weather stranded seven utility workers repairing power lines in the nearby Kuygan rural district, according to Tengrinews.

Kazakhstan has been one of Starlink’s more notable markets in Central Asia. Teslarati reported in 2024 that Starlink was serving 1,731 of the country’s 1,879 schools, with the country’s Education Minister saying it had set a new standard for internet service in schools.

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Rescue stories like this one have followed Starlink for years, usually in places where ground networks fail or never existed in the first place. Then Florida CFO Jimmy Patronis called Starlink a “game changer” for search and rescue crews during Hurricane Milton, and SpaceX and T-Mobile switched on Starlink Direct to Cell in North Carolina to push emergency alerts to phones after Hurricane Helene.

The next target is dead zones for people who do not carry a dish at all. SpaceX is building out Starlink Mobile and earlier this week selected Qualcomm to supply core infrastructure for a planned terrestrial 5G network in the United States, which it intends to pair with its next generation satellite constellation.

Sunday’s post is at least the third time Musk has written “Starlink saves lives” on X this week, following identical posts on November 5 and November 7.

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SpaceX will perform Starship double catch attempt with Flight 15

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Credit: SpaceX

SpaceX plans to attempt what will be a defining moment in rocket reusability on Starship Flight 15.

As Elon Musk announced in a recent X post, SpaceX will attempt to catch both the Super Heavy Booster and the Starship upper stage during the upcoming orbital flight. If successful, it will mark the first time that all parts of an orbital rocket return to Earth intact, a breakthrough Musk has called essential to making life multiplanetary.

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Previous flights have demonstrated the tower-catch technique with Super Heavy. SpaceX has successfully caught V1 boosters three times (on Flights 5, 7, and 8), with some even reflown. The Ship upper stage has never been caught.

Returning from orbital velocity after deploying payload makes it a significantly harder challenge due to higher energy, heat loads, and the need for precise belly-flop reentry, a flip maneuver, and a final landing burn to settle between the Mechazilla tower’s chopstick arms.

Flight 15, using Booster 22 and Ship 42 (both Block 3 vehicles), is targeted for no earlier than Friday, November 13, 2026, from Orbital Launch Pad 2 at Starbase, Texas. The 75-minute window opens at 4:45 p.m. CT, pending regulatory approval. After hot staging and separation, the booster is planned to return for a catch roughly 6 minutes and 35 seconds after liftoff.

The Ship will insert into a roughly 275 km orbit, deploy 26 advanced Starlink V3 satellites, complete about 14 orbits over more than 22 hours, and—if systems check out—perform a deorbit burn, reentry, flip, and landing burn for a tower catch at approximately T+22 hours 32 minutes.

SpaceX confirms Starship 15 launch window with massive ambitions

A simulation shown during SpaceX’s October earnings call depicted the Ship descending in a belly-flop attitude, flipping upright with a short engine burn, and being captured by the arms:

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Contingency splashdown zones exist in the Gulf of Mexico (booster) and Pacific (Ship) if a catch is not viable. SpaceX has stressed rigorous health checks before committing the Ship to a return-to-launch-site trajectory.

Musk has described the odds of success on this first dual-catch attempt as “more likely than not,” noting a steady stream of additional flights is already scheduled if needed. Full recovery would enable rapid inspection, refurbishment, and reflight—slashing costs and supporting the high launch cadence required for Starlink expansion, lunar missions, and eventual Mars settlement.

As Musk put it, this is “the critical breakthrough needed to make life multiplanetary.”

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SpaceX’s next Starship flight set to make history on Friday the 13th

SpaceX is targeting Friday, November 13 for Starship Flight 15 and its first ship catch.

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SpaceX is targeting Friday, November 13 for Starship Flight 15, the mission the company plans to use for its first attempt at catching the ship itself with the launch tower.

SpaceX Vice President of Launch Kiko Dontchev shared the date on stage at the UP.Summit on Thursday, according to Ars Technica’s Eric Berger, who was in attendance. It is the first launch target to come directly from a SpaceX executive. Until now, the public schedule had relied on FAA air traffic planning slides, which listed Flight 15 for no earlier than November 8 and later November 12. SpaceX has not posted an official mission page yet, and no launch time has been shared.

The date lands inside the window Elon Musk sketched out last month. Speaking at Giga Texas on October 10, Musk said the flight would “probably launch a little bit before Thanksgiving,” as Teslarati reported. On SpaceX’s third quarter earnings call ten days later, he confirmed that Flight 15 would try to catch both the Super Heavy booster and the ship, and put the odds of a successful ship catch at “more likely than not.” SpaceX also aired an animation of the maneuver during that webcast, showing the ship swinging vertical over Starbase before dropping into the tower’s chopsticks.

The hardware is ready. Booster 22 fired all 33 of its Raptor engines for a full duration static fire at Pad 2 on October 25. Ship 42 followed with a single engine burn simulating a deorbit maneuver on October 26 and a 60 second firing of all six engines the next day, according to NASASpaceflight. Ship 42 had already rehearsed the catch in September, when the Pad 2 arms lifted it into position and crews connected the quick disconnect arm while the vehicle hung from the tower.

The remaining hurdle is regulatory. The FAA’s Starship page does not yet list a Flight 15 license. SpaceX President Gwynne Shotwell said in October that, after “significant constructive engagement with the FAA,” she expects the license to cover a return to the launch site and a tower catch for both stages. Bringing the ship home means a reentry path that heads toward land, rather than ending over open ocean as every Starship flight so far has.

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SpaceX has caught Super Heavy three times, on Flights 5, 7 and 8, but the ship comes back from orbital velocity and has never been caught. Flight 14 on September 28 was the first Starship to reach orbit, deploying 26 Starlink V3 satellites before splashing down despite an early engine shutdown that Musk blamed on engine computer software.

Musk has called a successful ship catch “the first time that there’s been full recovery of an orbital class rocket,” and he has already named the step after it: a Flight 16 where both the booster and the ship fly again. NASASpaceflight reports that Ship 43, the next vehicle in line, is set for static fire testing in December.

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