SpaceX
3D-printed Mars habitat could be a perfect fit for early SpaceX Starship colonies
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.
- An overview of a potential Mars base built around the MARSHA habitat design. (AI SpaceFactory & PLOMP)
- A glimpse into one floor of MARSHA’s Mars habitat interior. (AI SpaceFactory & PLOMP)
- A number of BFR (2018) spaceships seen landed at a future Mars base. (SpaceX)
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.
- AI SpaceFactory’s alluring vision of one route to humans living on Mars.
- A cutaway view of MARSHA at Martian dusk. (AI SpaceFactory)
- An outline of the main features of SpaceX’s “Mars Architecture”, present by Paul Wooster in August 2018. (SpaceX)
- An overview of an early SpaceX Mars colony, circa 2017. (SpaceX)
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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Elon Musk
TIME honors SpaceX’s Gwynne Shotwell: From employee No. 7 to world’s most valuable company
Time Magazine honors Gwynne Shotwell as SpaceX reaches a $1.25 trillion valuation and eyes its IPO.
TIME Magazine has put SpaceX President and COO Gwynne Shotwell on its cover, and the timing could not be more fitting. Published today, the profile of Shotwell arrives at a moment when the company she has quietly run for more than two decades stands at the center of the most consequential developments in aerospace, artificial intelligence, and the future of human civilization.
Shotwell joined SpaceX in 2002 as its seventh employee and has never stopped expanding her role. She oversees day-to-day operations across multiple executive teams spanning Falcon, Starlink, Starship, and now xAI following SpaceX’s February 2026 merger with Elon Musk’s artificial intelligence company, a deal that made SpaceX the world’s most valuable private company at a reported valuation of $1.25 trillion. A highly anticipated IPO is expected in the second quarter of 2026.
Will Tesla join the fold? Predicting a triple merger with SpaceX and xAI
Her track record is historic. She oversaw the first landing of an orbital rocket’s first stage, the first reuse and re-landing of an orbital booster, and the first private crewed launch to Earth orbit in May 2020. She built the Falcon launch manifest from nothing to more than 170 contracted missions representing over $20 billion in business. Under her operational leadership, SpaceX completed 96 successful missions in 2023 alone and has now flown more than 20 crewed Falcon 9 missions. Starlink, which she championed as a financial pillar of the company long before it was a mainstream topic, now connects tens of millions of users worldwide and provided a critical communications lifeline to Ukraine following the 2022 invasion.
Elon Musk has never been shy about what Shotwell means to him and to SpaceX. When she shared her vision for worldwide internet connectivity through Starlink, Musk responded on X with a simple statement, “Gwynne is awesome.” It is a sentiment that has been echoed across the industry. NASA Administrator Bill Nelson once said of Musk: “One of the most important decisions he made, as a matter of fact, is he picked a president named Gwynne Shotwell. She runs SpaceX. She is excellent.”
Gwynne is awesome https://t.co/tiXtMWJmPE
— Elon Musk (@elonmusk) September 28, 2024
Now, with Starship targeting its first crewed lunar landing under the Artemis program by 2028, an xAI integration underway, and a pending IPO that could reshape capital markets, Shotwell’s mandate has never been larger. She told Time that 18 Starships are already in various stages of construction at Starbase. “By 2028,” she said, gesturing across the factory floor, “these should be long gone. They better have flown by then.” If Shotwell’s history at SpaceX is any guide, they will.
Elon Musk
SpaceX’s IPO might arrive sooner than you think
Musk has hinted for years that an eventual public offering was inevitable, though he has stressed the need to maintain operational focus. Insiders have told outlets that the CEO is pushing for a significant retail investor allocation, reportedly more than 20 percent of shares, and tighter lock-up periods to limit early selling pressure.
Elon Musk’s SpaceX is on the verge of one of the most anticipated Initial Public Offerings (IPO) in history.
However, a new report from The Information indicates the rocket and satellite giant is aiming to file its IPO prospectus with U.S. regulators as soon as this week, or early next week at the latest.
People familiar with the plans told The Information that advisers involved in the process expect the IPO could raise more than 75 billion dollars, potentially making it the largest stock market debut ever and eclipsing Saudi Aramco’s 29.4 billion dollar offering in 2019.
The filing would mark the formal start of what has long been rumored: SpaceX’s transition from a closely held private powerhouse to a publicly traded company.
The timing aligns with earlier signals.
In late February, Bloomberg reported that SpaceX was targeting a confidential IPO filing in March and a possible public listing in June, with a valuation north of 1.75 trillion dollars. At the time, the company’s private valuation hovered around 1.25 trillion dollars.
SpaceX considering confidential IPO filing this March: report
Starlink, SpaceX’s satellite internet constellation, has been the primary driver of that surge, now serving millions of customers worldwide and generating steady revenue. Recent Starship test flights and a record pace of Falcon launches have further bolstered investor confidence.
Musk has hinted for years that an eventual public offering was inevitable, though he has stressed the need to maintain operational focus. Insiders have told outlets that the CEO is pushing for a significant retail investor allocation, reportedly more than 20 percent of shares, and tighter lock-up periods to limit early selling pressure.
A June listing would give SpaceX immediate access to public capital markets at a moment when demand for space-related stocks remains high. It would also allow early employees and long-time investors to cash out portions of their stakes while giving everyday shareholders a chance to own a piece of the company behind reusable rockets, global broadband, and NASA contracts.
Of course, nothing is certain until the SEC filing appears. Market conditions, regulatory reviews, and Musk’s own schedule could still shift timelines.
Yet the latest word from The Information suggests the window has opened. If the filing lands this week, SpaceX’s roadshow could begin in earnest within weeks, setting the stage for what many analysts already call the IPO of the decade.
Elon Musk
Elon Musk’s TERAFAB project: Everything you need to know
The CEO has hinted heavily for several quarters that it would probably need to produce its own computing power to stay up to speed on the demand it is facing for its projects. It is now taking matters into its own hands.
On Sunday, Elon Musk formally made TERAFAB official—a groundbreaking $20-25 billion joint venture uniting Tesla, SpaceX, and xAI, three of the world’s richest man’s most significant and powerful ventures.
Musk described the project as “the most epic chip building exercise in history by far.”
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
The initiative aims to produce over one terawatt of AI compute annually, dwarfing the global industry’s current output of roughly 20 gigawatts per year. Musk framed the effort as “the next step towards becoming a galactic civilization,” positioning it as essential for scaling humanity into a multi-planetary species.
The Need for TERAFAB
Existing chip suppliers such as TSMC, Samsung, and Micron cannot expand quickly enough to meet the explosive demand for AI hardware.
We’re building TERAFAB to close the gap between today’s chip production & the future’s demand – a future among the stars.
Join us → https://t.co/512DIlqNgY pic.twitter.com/ATr0e0pRDJ
— SpaceX (@SpaceX) March 22, 2026
Musk explained the situation clearly:
“We’re very grateful to our existing supply chain… but there’s a maximum rate at which they’re comfortable expanding. We either build the Terafab or we don’t have the chips, and we need the chips, so we build the Terafab.”
The CEO has hinted heavily for several quarters that it would probably need to produce its own computing power to stay up to speed on the demand it is facing for its projects. It is now taking matters into its own hands.
Chip Types and Production Goals
The facility will manufacture two specialized chip families, according to the presentation:
- Edge-inference AI5 and AI6 processors optimized for Tesla’s Optimus humanoid robots and Full Self-Driving systems in vehicles and Robotaxis
- High-power D3 chips hardened for space environments
Musk outlined annual output targets, which are between 100 and 200 gigawatts of terrestrial compute for robotics, supporting Musk’s vision of producing 1-10 billion Optimus units per year, and the majority (80%) of chips dedicated to orbital AI data centers. Overall, TERAFAB aims to produce 100-200 billion custom AI and memory chips each year.
Scale and Strategy
The size of the TERAFAB project will be remarkable, as Musk indicated after the presentation that the entire Gigafactory Texas campus would not be large enough to fit the needs of the project. In fact, Musk said it would be around 100 million square feet in size, the equivalent of 15 Pentagons or three Central Parks.
Yes, the one in New York City.
Construction will begin with an “advanced technology fab” on the Giga Texas campus in Austin, enabling rapid iteration: design a chip, fabricate lithography masks, produce and test wafers, all within days.
However, the full-scale TERAFAB requires thousands of acres and over 10 gigawatts of power, far exceeding what Giga Texas can accommodate. Musk stated:
“We couldn’t possibly fit the Terafab on the GigaTexas campus. It will be far bigger than everything else combined there.”
Multiple large sites are currently under consideration, but this will need a sprawling land mass to get started.
The sheer scale of TERAFAB is going to be insane.
Elon said it wouldn’t be suitable for anywhere on Giga Texas property because it’s too big:
“We couldn’t possibly fit the Terafab on the GigaTexas campus. It will be far bigger than everything else combined there.
Several… pic.twitter.com/79GbhNNuf4
— TESLARATI (@Teslarati) March 23, 2026
Key Applications
TERAFAB will be a crucial part of the development of some of Tesla’s most valuable projects, including Optimus and data center development, especially from an orbital standpoint. For that reason, we will break this down into Terrestrial and Orbital applications:
- Terrestrial: Powers autonomous vehicle fleets and billions of Optimus robots performing physical labor
- Orbital: Starship will launch massive AI satellite constellations, starting with 100-kilowatt “Mini” units, and scaling to larger Megawatt models, creating the world’s largest data center in low-Earth orbit.
Space-based advantages include five times greater solar irradiance, efficient vacuum heat rejection, and freedom from terrestrial grid constraints (U.S. electricity generation totals just 0.5 terawatts). Musk emphasized the principle:
“Quantity has a quality all its own.”
We wrote about SpaceX’s recent filing with the FCC for 1 million orbital data center plans.
Strategic Vision
TERAFAB represents vertical integration at an unprecedented scale, combining AI hardware, robotics, and orbital infrastructure.
Musk described the project as “the final missing piece of the puzzle.” With production ramping toward 2027, TERAFAB is set to accelerate an era of abundance, transforming science fiction into reality and positioning Musk’s companies at the forefront of galactic-scale innovation.







