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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 and Elon Musk share insights on Starship Ship 36’s RUD

Starship Ship 36 experienced a Rapid Unscheduled Disassembly during a static fire attempt.

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Elon Musk and SpaceX provided an explanation for the Rapid Unscheduled Disassembly (RUD) of Starship Ship 36 on Wednesday. As per Musk, preliminary data suggests that a nitrogen composite overwrapped pressure vessel (COPV) in the vehicle’s payload bay failed below its proof pressure.

On Wednesday evening, Ship 36 experienced a RUD during a static fire attempt. Videos of the incident that were shared online showed Starship Ship 36 exploding into a massive fireball at its launchpad in Starbase, Texas. Images taken in the aftermath of the explosion showed significant damage to the plumbing in the area. The site’s pad structure was also destroyed.

Elon Musk shared some information immediately after the incident. In a response to a post from space enthusiast @Erdayastronaut, Musk stated that “Preliminary data suggests that a nitrogen COPV in the payload bay failed below its proof pressure.”

Musk also noted that, “If further investigation confirms that this is what happened, it is the first time ever for this design.”

SpaceX provided more insight into the incident in a post on its official website.

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“After completing a single-engine static fire earlier this week, the vehicle was in the process of loading cryogenic propellant for a six-engine static fire when a sudden energetic event resulted in the complete loss of Starship and damage to the immediate area surrounding the stand.

“The explosion ignited several fires at the test site, which remains clear of personnel and will be assessed once it has been determined to be safe to approach. Individuals should not attempt to approach the area while safing operations continue,” SpaceX wrote in its post.

SpaceX highlighted that despite Starship Ship 36’s RUD, the incident will not result in any hazards to the surrounding communities in the Rio Grande Valley. And in a post on X, SpaceX also confirmed that everyone in the Starship team was safe and accounted for after Ship 36’s explosion.

While Ship 36’s RUD is a speed bump for the Starship program, SpaceX is a company that is known to grow stronger with every adversity. Thus, it would not be surprising if SpaceX implemented numerous improvements to Starship after this incident–improvements that would make the vehicle more reliable and safer than before.

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SpaceX President meets India Minister after Starlink approval

Starlink’s India debut gets a boost as Gwynne Shotwell meets Comms Minister Scindia. Talks focused on Digital India’s goals.

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SpaceX’s Starlink India expansion gained momentum as SpaceX President and COO Gwynne Shotwell met with Communications Minister Jyotiraditya Scindia on Tuesday, following the company’s recent telecom license approval. The discussions focused on satellite communications to advance Digital India’s connectivity goals.

“Had a productive meeting with Ms. Gwynne Shotwell, President & COO of SpaceX, on India’s next frontier in connectivity. We delved into opportunities for collaboration in satellite communications to power Digital India’s soaring ambitions and empower every citizen across the country,” Scindia said.

India’s Communications Minister emphasized the transformative potential of satellite technologies, while Shotwell expressed gratitude for the license. Scindia noted: “Ms. Shotwell appreciated the license granted to Starlink, calling it a great start to the journey.”

Starlink India cleared a major regulatory hurdle after the Department of Telecommunications granted it a Global Mobile Personal Communication by Satellite (GMPCS) license. SpaceX secured the approval after a three-year wait.

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In April, Starlink executives, including Vice President Chad Gibbs and Senior Director Ryan Goodnight, met Commerce Minister Piyush Goyal to discuss investments and partnerships, laying the groundwork for market entry. India’s satellite internet sector is heating up, with Eutelsat OneWeb and Reliance Jio also securing licenses, while Amazon’s Kuiper awaits approval.

Starlink India’s license enables SpaceX to initiate commercial operations within two months. The service will reportedly offer high-speed internet for ₹3,000 per month with unlimited data, requiring a ₹33,000 hardware kit, including a dish and router, targeting underserved and remote regions.

Starlink’s entry into India builds on its global network of over 7,000 satellites, designed to deliver low-latency internet to areas with limited broadband access. The company’s collaboration with Indian authorities and telecom giants like Reliance Jio and Bharti Airtel for distribution underscores its commitment to bridging the digital divide.

As Starlink prepares to launch services, its discussions with Scindia signal deepening ties with India’s government to support Digital India’s vision. “Satellite technologies are relevant and transformative,” Scindia noted, highlighting their role in empowering citizens. Starlink’s India expansion positions it to compete in a growing market, driving innovation and connectivity for millions in rural and remote areas.

 

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SpaceX Ax-4 Mission prepares for ISS with new launch date

SpaceX, Axiom Space, and NASA set new launch date for the Ax-4 mission after addressing ISS & rocket concerns.

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(Credit: SpaceX)

SpaceX is preparing for a new launch date for the Ax-4 mission to the International Space Station (ISS).

SpaceX, Axiom Space, and NASA addressed recent technical challenges and announced a new launch date of no earlier than Thursday, June 19, for the Ax-4 mission. The delay from June 12 allowed teams to assess repairs to small leaks in the ISS’s Zvezda service module.

NASA and Roscosmos have been monitoring leaks in the Zvezda module’s aft (back) segment for years. However, stable pressure could also result from air flowing across the hatch seal from the central station. As NASA and its partners adapt launch schedules to ensure station safety, adjustments are routine.

“Following the most recent repair, pressure in the transfer tunnel has been stable,” a source noted, suggesting the leaks may be sealed.

“By changing pressure in the transfer tunnel and monitoring over time, teams are evaluating the condition of the transfer tunnel and the hatch seal between the space station and the back of Zvezda,” the source added.

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SpaceX has also resolved a liquid oxygen leak found during post-static fire inspections of the Falcon 9 rocket, completing a wet dress rehearsal to confirm readiness. The Ax-4 mission is Axiom Space’s fourth private astronaut trip to the ISS. It will launch from NASA’s Kennedy Space Center in Florida on a Falcon 9 rocket with a new Crew Dragon capsule.

“This is the first flight for this Dragon capsule, and it’s carrying an international crew—a perfect debut. We’ve upgraded storage, propulsion components, and the seat lash design for improved reliability and reuse,” said William Gerstenmaier, SpaceX’s vice president of build and flight reliability.

The Ax-4 mission crew is led by Peggy Whitson, Axiom Space’s director of human spaceflight and former NASA astronaut. The Ax-4 crew includes ISRO astronaut Shubhanshu Shukla as pilot, alongside mission specialists Sławosz Uznański-Wiśniewski from Poland and Tibor Kapu from Hungary. The international team underscores Axiom’s commitment to global collaboration.

The Ax-4 mission will advance scientific research during its ISS stay, supporting Axiom’s goal of building a commercial space station. As teams finalize preparations, the mission’s updated launch date and technical resolutions position it to strengthen private space exploration’s role in advancing space-based innovation.

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