Researchers at the German Aerospace Center (DLR) have developed MiniFix, a fully 3D printed syringe-based biological fixation system engineered for spaceflight. Successfully deployed in five MAPHEUS sounding rocket missions, MiniFix represents a breakthrough in experimental payload design, combining rapid prototyping, modularity, and robust performance in microgravity environments, combining rapid prototyping with modular, lightweight, and reliable performance under the extreme conditions of microgravity research. A 3D printing milestone for space life science Unlike conventional biological fixation systems, MiniFix is entirely produced via Fused Deposition Modeling (FDM). Key components, including the syringe holders, baseplate, and housing, were fabricated using desktop 3D printers, notably a Prusa MK3+, with 0.4 mm nozzles and a 0.3 mm layer height. This approach enabled fast, low-cost iteration and customization of parts to suit different missions and experimental needs. The system has undergone structural revisions using three different filaments; PLA (Polylactic Acid), used in initial missions (MAPHEUS-09 and -12), PETG (Polyethylene Terephthalate Glycol), chosen for enhanced mechanical durability (MAPHEUS-14), and GreenTEC Pro, a compostable bioplastic with high thermal resistance, used in MAPHEUS-15. This made MiniFix the first biologically compostable experiment structure to fly aboard a rocket. Sectional, translucent view through the MiniFix fixation system. Image via Sebastian Feles / DLR. Modular design for rapid adaptation MiniFix features a dual-syringe configuration, where a fixative and a biological sample are housed in vertically stacked syringes. Syringe actuation is handled by NEMA11 stepper motors coupled with linear actuators, allowing precise fluid dispensing. The hardware is modular and sterilizable, enabling pre-assembled syringe units to be installed under sterile conditions. Its all-3D printed chassis ensures that custom features, like integrated lighting for plant experiments, can be introduced quickly without redesigning the core system. This makes MiniFix suitable for various biological models, from unicellular organisms to organoids. Variants of the SBBFS Configuration. Image via Sebastian Feles / DLR. Built-in thermal regulation via waste heat A standout innovation is MiniFix’s passive thermal management system, which uses the heat generated by its stepper motors to maintain stable internal temperatures. With no need for separate heating elements, this system simplifies design, reduces power draw, and lowers overall payload mass, critical factors for sounding rocket missions with strict weight and energy budgets. Test data from MAPHEUS-15 showed that MiniFix maintained an internal temperature of 21.98 °C ±0.12 °C, consuming just 4.6 Wh during operation, even under ambient conditions as low as 4 °C. Space-tested reliability The reliability of this 3D printed structure was put to the test across multiple missions. MiniFix successfully endured extreme conditions, including launch vibrations exceeding 20 g and temperature swings from hypergravity to microgravity and re-entry. Across four missions, its components have shown no degradation or material failure, with post-flight inspections confirming the integrity of all printed parts and mechanical systems. Future applications Beyond fixation, MiniFix could evolve into a general-purpose liquid handling system for space. Its syringe mechanism is already capable of performing programmable mixing and the platform could be adapted for reagent delivery, drug testing, or even microfluidics in space-based manufacturing. Additionally, it exemplifies how additive manufacturing can accelerate experimental development cycles while maintaining reliability in harsh environments. Its open-source microcontroller and modular design ethos further position it as a template for future experimental hardware in life sciences and beyond.3D printing gains traction in space hardware development Additive manufacturing is rapidly transforming the development of spaceflight hardware, from on‑orbit part fabrication to ground-based launch systems. Just this year, ESA’s Metal3D printer aboard the ISS produced the first metal 3D‑printed part in microgravity, now safely back on Earth for analysis. Meanwhile, Nikon and JAXA are collaborating to refine large-scale metal 3D printing for space components, advancing materials and process control to shorten lead times and reduce launch costs. Within this context, DLR’s MiniFix system exemplifies a new wave of highly adaptable, mission‑specific payloads, completely fabricated using desktop FDM printers and bioplastics, optimized for the rigors of sounding rocket flight and microgravity research. The full research paper, titled “Pioneering the Future of Experimental Space Hardware,” is available in Microgravity Science and Technology via Springer Nature. Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Featured image shows sectional, translucent view through the MiniFix fixation system. Image via Sebastian Feles / DLR.

Published May 18, 2025 6:00am EDT close New space capsule just changed the game for bringing stuff back from orbit A European startup successfully completed the first orbital test flight of its Phoenix 1 re-entry space capsule. While the United States has long been a leader in space exploration and commercial launches, Europe is now making significant strides of its own. Recently, a major milestone was achieved when Atmos Space Cargo, a European startup, successfully completed the first orbital test flight of its Phoenix 1 re-entry space capsule. This mission, which launched from Cape Canaveral, Florida, as part of a SpaceX Falcon 9 rideshare, marks a new chapter in global space logistics. By demonstrating that Europe can develop and operate advanced return technology, Atmos is helping to make space more accessible and efficient for researchers, businesses and innovators on both sides of the Atlantic. This achievement signals the arrival of a new player in the space return market and opens the door to greater collaboration and competition in the rapidly growing field of commercial space logistics.JOIN THE FREE CYBERGUY REPORT: GET MY EXPERT TECH TIPS, CRITICAL SECURITY ALERTS AND EXCLUSIVE DEALS — PLUS INSTANT ACCESS TO MY FREE ULTIMATE SCAM SURVIVAL GUIDE WHEN YOU SIGN UP! Phoenix 1   (Atmos Space Cargo)The mission: From launch to splashdownPhoenix 1 launched aboard a SpaceX Falcon 9 rocket from Cape Canaveral, Florida, as part of the Bandwagon-3 rideshare mission. After reaching a 45-degree inclination orbit, the capsule completed one full trip around Earth. A carefully timed de-orbit maneuver then sent Phoenix 1 back toward the planet. During its descent, the capsule deployed an innovative inflatable heat shield, a technology designed by Atmos to protect the capsule during the intense heat and friction of reentry. FIRST PRIVATE SPACEX POLAR MISSION SPLASHES DOWN NEAR CALIFORNIAAs Phoenix 1 reentered Earth's atmosphere, it transmitted critical system and payload data to ground stations in South America. The capsule splashed down in the Atlantic Ocean, about 1,240 miles off the Brazilian coast. Because of the remote landing location, recovery of the capsule was not planned. However, the mission's main objectives were met, and the data collected is now being analyzed to inform future missions. Phoenix 1  (Atmos Space Cargo)Why Phoenix 1 is a big milestoneThe success of Phoenix 1 establishes Atmos as the fastest-moving private space logistics company in Europe to conduct an orbital return mission. This achievement demonstrates that Europe is on the path to developing independent, sovereign return capabilities. It also shows that private industry can lead the way in building essential space infrastructure. Atmos' rapid prototyping approach allowed the team to develop, qualify and fly Phoenix 1 in less than a year. This speed is almost unheard of in the space industry and highlights the company's commitment to innovation and hands-on problem-solving. The mission also proved that multinational collaboration is possible, as teams from around Europe worked together to achieve a common goal. Phoenix 1   (Atmos Space Cargo)What was learned and testedThe Phoenix 1 mission had several core objectives. The team aimed to collect in-flight data from the capsule and its subsystems while in orbit. The mission also carried scientific and commercial payloads, including technology demonstrators and biological experiments from partners such as Frontier Space, Imperial College London, DLR and IDDK. Another key goal was to deploy and test the inflatable heat shield under real reentry conditions. Although some data from the final stage of descent could not be retrieved due to the splashdown location, the mission still provided valuable insights. The data received from the capsule has already contributed to the development of Phoenix 2, the next-generation capsule planned for launch in 2026.SPACEX LAUNCH SCRUBBED HOURS AFTER HEGSETH SHARES MESSAGE TO RESCUE MISSION CREW: ‘WISH YOU GODSPEED’ Phoenix 1 (Atmos Space Cargo)The technology: Inflatable heat shield and rapid prototypingThe inflatable heat shield is a breakthrough in reentry technology. Traditional capsules rely on heavy, single-use heat shields or parachutes to survive reentry. Atmos' design is lighter, more efficient and potentially reusable, which could dramatically reduce the cost and complexity of returning cargo from space. Atmos' development philosophy is based on rapid prototyping and real-world testing. The team believes in building and testing hardware quickly, learning from each iteration and making improvements based on real data rather than relying solely on simulations. This approach allowed Phoenix 1 to go from concept to space in record time. Phoenix 1   (Atmos Space Cargo)The road aheadAtmos is already working on Phoenix 2, which will include its own propulsion system. This upgrade will allow the capsule to control its reentry trajectory and choose its splashdown zone, making recovery much easier and more practical. The company's vision is to create a flexible, cost-efficient and reliable logistics platform for space, supporting both commercial and institutional missions. With a payload efficiency of 1:2, Phoenix already offers the highest mass efficiency on the market. This opens new opportunities for microgravity research, in-space manufacturing and biotechnology. The technology will also support Europe's defense sector and strengthen the continent's independent space infrastructure. Phoenix 1  (Atmos Space Cargo)What this means for youThe success of Phoenix 1 is not just a technical achievement for engineers and scientists. It has the potential to assist with many aspects of everyday life. Faster and more affordable access to space means that new technologies, medicines and materials can be developed and tested in microgravity and then brought back to Earth for use.Universities, startups and small companies will have more opportunities to conduct experiments in space without the high costs and long wait times that have been barriers in the past. Atmos Space Cargo's growing space capabilities could also lead to new jobs, investment and technological leadership. Phoenix 1   (Atmos Space Cargo)Kurt's key takeawaysPhoenix 1's successful mission is a sign that space is becoming more accessible and that innovation is happening at an unprecedented pace. By proving that rapid development and new ideas can work in the challenging environment of space, Atmos Space Cargo is paving the way for a future where space logistics are as routine as shipping goods across continents. The next generation of breakthroughs in science and technology may very well start their journey with a ride on a capsule like Phoenix.CLICK HERE TO GET THE FOX NEWS APPDo you think the United States should accelerate its own space return technology to stay ahead, or is international competition good for innovation? Let us know by writing us atCyberguy.com/ContactFor more of my tech tips and security alerts, subscribe to my free CyberGuy Report Newsletter by heading to Cyberguy.com/NewsletterAsk Kurt a question or let us know what stories you'd like us to coverFollow Kurt on his social channelsAnswers to the most asked CyberGuy questions:New from Kurt:Copyright 2025 CyberGuy.com.  All rights reserved.   Kurt "CyberGuy" Knutsson is an award-winning tech journalist who has a deep love of technology, gear and gadgets that make life better with his contributions for Fox News & FOX Business beginning mornings on "FOX & Friends." Got a tech question? 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