alternative_right shares a report from Phys.Org: Using conventional propulsion and low-energy trajectories, it takes six to nine months for crewed spacecraft to reach Mars. These durations complicate mission design and technology requirements and raise health and safety concerns since crews will be exposed to extended periods in microgravity and heightened exposure to cosmic radiation. Traditionally, mission designers have recommended nuclear-electric or nuclear-thermal propulsion (NEP/NTP), which could shorten trips to just 3 months. In a recent study, a UCSB physics researcher identified two trajectories that could reduce transits to Mars using the Starship to between 90 and 104 days. The study was authored by Jack Kingdon, a graduate student researcher in the Physics Department at the University of California, Santa Barbara (UCSB). He is also a member of the UCSB Weld Lab, an experimental ultracold atomic physics group that uses quantum degenerate gases to explore quantum mechanical phenomena. [...] As outlined on its website, conference presentations, and user manual, the SpaceX mission architecture consists of six Starships traveling to Mars. Four of these spacecraft will haul 400 metric tons (440 U.S. tons) of cargo while two will transport 200 passengers. Based on the Block 2 design, which has a 1,500 metric ton (1,650 U.S. ton) propellant capacity, the crewed Starships will require 15 tankers to fully refuel in low Earth orbit (LEO). The cargo ships would require only four, since they would be sent on longer low-energy trajectories. Once the flotilla arrives at Mars, the Starships will refuel using propellant created in situ using local carbon dioxide and water ice. When the return window approaches, one of the crew ships and 3-4 cargo ships will refuel and then launch into a low Mars orbit (LMO). The cargo ships will then transfer the majority of their propellant to the crew ship and return to the surface of Mars. The crew ship would then depart for Earth, and the process could be repeated for the other crew ship. Kingdon calculated multiple trajectories using a Lambert Solver, which produces the shortest elliptical arc in two-body problem equations (aka Lambert's problem). The first would depart Earth on April 30th, 2033, taking advantage of the 26-month periodic alignment between Earth and Mars. The transit would last 90 days, with the crew returning to Earth after another 90-day transit by July 2nd, 2035. The second would depart Earth on July 15th, 2035, and return to Earth after a 104-day transit on December 5th, 2037. As Kingdon explained, the former trajectory is the most likely to succeed: "The optimal trajectory is the 2033 trajectory -- it has the lowest fuel requirements for the fastest transit time. A note that may not be obvious to the layreader is that Starship can very easily reach Mars in ~3 months -- in fact, it can in any launch window, over a fairly wide range of trajectories. However, Starship may impact the Martian atmosphere too fast (although we do not know, and likely SpaceX don't either actually how fast Starship can hit the Martian atmosphere and survive). The trajectories discussed are ones that I am confident Starship will survive." The paper describing the work has been published in the journal Scientific Reports. Read more of this story at Slashdot.

June 3, 20255 min readAre We Ready for Death in Space?NASA has quietly taken steps to prepare for a death in space. We need to ask how nations will deal with this inevitability now, as more people start traveling off the planetBy Peter Cummings edited by Lee Billings SciePro/Science Photo Library/Getty ImagesIn 2012 NASA stealthily slipped a morgue into orbit.No press release. No fanfare. Just a sealed, soft-sided pouch tucked in a cargo shipment to the International Space Station (ISS) alongside freeze-dried meals and scientific gear. Officially, it was called the Human Remains Containment Unit (HRCU). To the untrained eye it looked like a shipping bag for frozen cargo. But to NASA it marked something far more sobering: a major advance in preparing for death beyond Earth.As a kid, I obsessed over how astronauts went to the bathroom in zero gravity. Now, decades later, as a forensic pathologist and a perennial applicant to NASA’s astronaut corps, I find myself fixated on a darker, more haunting question:On supporting science journalismIf you're enjoying this article, consider supporting our award-winning journalism by subscribing. By purchasing a subscription you are helping to ensure the future of impactful stories about the discoveries and ideas shaping our world today.What would happen if an astronaut died out there? Would they be brought home, or would they be left behind? If they expired on some other world, would that be their final resting place? If they passed away on a spacecraft or space station, would their remains be cast off into orbit—or sent on an escape-velocity voyage to the interstellar void?NASA, it turns out, has begun working out most of these answers. And none too soon. Because the question itself is no longer if someone will die in space—but when.A Graying CorpsNo astronaut has ever died of natural causes off-world. In 1971 the three-man crew of the Soviet Soyuz 11 mission asphyxiated in space when their spacecraft depressurized shortly before its automated atmospheric reentry—but their deaths were only discovered once the spacecraft landed on Earth. Similarly, every U.S. spaceflight fatality to date has occurred within Earth’s atmosphere—under gravity, oxygen and a clear national jurisdiction. That matters, because it means every spaceflight mortality has played out in familiar territory.But planned missions are getting longer, with destinations beyond low-Earth orbit. And NASA’s astronaut corps is getting older. The average age now hovers around 50—an age bracket where natural death becomes statistically relevant, even for clean-living fitness buffs. Death in space is no longer a thought experiment. It’s a probability curve—and NASA knows it.In response, the agency is making subtle but decisive moves. The most recent astronaut selection cycle was extended—not only to boost intake but also to attract younger crew members capable of handling future long-duration missions.NASA’s Space MorgueIf someone were to die aboard the ISS today, their body would be placed in the HRCU, which would then be sealed and secured in a nonpressurized area to await eventual return to Earth.The HRCU itself is a modified version of a military-grade body bag designed to store human remains in hazardous environments. It integrates with refrigeration systems already aboard the ISS to slow decomposition and includes odor-control filters and moisture-absorbent linings, as well as reversed zippers for respectful access at the head. There are straps to secure the body in a seat for return, and patches for name tags and national flags.Cadaver tests conducted in 2019 at Sam Houston State University have proved the system durable. Some versions held for over 40 days before decomposition breached the barrier. NASA even drop-tested the bag from 19 feet to simulate a hard landing.But it’s never been used in space. And since no one yet knows how a body decomposes in true microgravity (or, for that matter, on the moon), no one can really say whether the HRCU would preserve tissue well enough for a forensic autopsy.This is a troubling knowledge gap, because in space, a death isn’t just a tragic loss—it’s also a vital data point. Was an astronaut’s demise from a fluke of their physiology, or an unavoidable stroke of cosmic bad luck—or was it instead a consequence of flaws in a space habitat’s myriad systems that might be found and fixed? Future lives may depend on understanding what went wrong, via a proper postmortem investigation.But there’s no medical examiner in orbit. So NASA trains its crews in something called the In-Mission Forensic Sample Collection protocol. The space agency’s astronauts may avoid talking about it, but they all have it memorized: Document everything, ideally with real-time guidance from NASA flight surgeons. Photograph the body. Collect blood and vitreous fluid, as well as hair and tissue samples. Only then can the remains be stowed in the HRCU.NASA has also prepared for death outside the station—on spacewalks, the moon or deep space missions. If a crew member perishes in vacuum but their remains are retrieved, the body is wrapped in a specially designed space shroud.The goal isn’t just a technical matter of preventing contamination. It’s psychological, too, as a way of preserving dignity. Of all the “firsts” any space agency hopes to achieve, the first-ever human corpse drifting into frame on a satellite feed is not among them.If a burial must occur—in lunar regolith or by jettisoning into solar orbit—the body will be dutifully tracked and cataloged, treated forevermore as a hallowed artifact of space history.Such gestures are also of relevance to NASA’s plans for off-world mourning; grief and memorial protocols are now part of official crew training. If a death occurs, surviving astronauts are tasked with holding a simple ceremony to honor the fallen—then to move on with their mission.Uncharted RealmsSo far we’ve only covered the “easy” questions. NASA and others are still grappling with harder ones.Consider the issue of authority over a death and mortal remains. On the ISS, it’s simple: the deceased astronaut’s home country retains jurisdiction. But that clarity fades as destinations grow more distant and the voyages more diverse: What really happens on space-agency missions to the moon, or to Mars? How might rules change for commercial or multinational spaceflights—or, for that matter, the private space stations and interplanetary settlements that are envisioned by Elon Musk, Jeff Bezos and other tech multibillionaires?NASA and its partners have started drafting frameworks, like the Artemis Accords—agreements signed by more than 50 nations to govern behavior in space. But even those don’t address many intimate details of death.What happens, for instance, if foul play is suspected?The Outer Space Treaty, a legal document drafted in 1967 under the United Nations that is humanity’s foundational set of rules for orbit and beyond, doesn’t say.Of course, not everything can be planned for in advance. And NASA has done an extraordinary job of keeping astronauts in orbit alive. But as more people venture into space, and as the frontier stretches to longer voyages and farther destinations, it becomes a statistical certainty that sooner or later someone won’t come home.When that happens, it won’t just be a tragedy. It will be a test. A test of our systems, our ethics and our ability to adapt to a new dimension of mortality. To some, NASA’s preparations for astronautical death may seem merely morbid, even silly—but that couldn’t be further from the truth.Space won’t care of course, whenever it claims more lives. But we will. And rising to that grim occasion with reverence, rigor and grace will define not just policy out in the great beyond—but what it means to be human there, too.

Observation Rocket Report: SpaceX’s expansion at Vandenberg; India’s PSLV fails in flight China's diversity in rockets was evident this week, with four types of launchers in action. Stephen Clark – May 23, 2025 7:00 am | 7 Dawn Aerospace's Mk-II Aurora airplane in flight over New Zealand last year. Credit: Dawn Aerospace Dawn Aerospace's Mk-II Aurora airplane in flight over New Zealand last year. Credit: Dawn Aerospace Story text Size Small Standard Large Width * Standard Wide Links Standard Orange * Subscribers only   Learn more Welcome to Edition 7.45 of the Rocket Report! Let's talk about spaceplanes. Since the Space Shuttle, spaceplanes have, at best, been a niche part of the space transportation business. The US Air Force's uncrewed X-37B and a similar vehicle operated by China's military are the only spaceplanes to reach orbit since the last shuttle flight in 2011, and both require a lift from a conventional rocket. Virgin Galactic's suborbital space tourism platform is also a spaceplane of sorts. A generation or two ago, one of the chief arguments in favor of spaceplanes was that they were easier to recover and reuse. Today, SpaceX routinely reuses capsules and rockets that look much more like conventional space vehicles than the winged designs of yesteryear. Spaceplanes are undeniably alluring in appearance, but they have the drawback of carrying extra weight (wings) into space that won't be used until the final minutes of a mission. So, do they have a future? As always, we welcome reader submissions. If you don't want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets, as well as a quick look ahead at the next three launches on the calendar. One of China's commercial rockets returns to flight. The Kinetica-1 rocket launched Wednesday for the first time since a failure doomed its previous attempt to reach orbit in December, according to the vehicle's developer and operator, CAS Space. The Kinetica-1 is one of several small Chinese solid-fueled launch vehicles managed by a commercial company, although with strict government oversight and support. CAS Space, a spinoff of the Chinese Academy of Sciences, said its Kinetica-1 rocket deployed multiple payloads with "excellent orbit insertion accuracy." This was the seventh flight of a Kinetica-1 rocket since its debut in 2022. Back in action ... "Kinetica-1 is back!" CAS Space posted on X. "Mission Y7 has just successfully sent six satellites into designated orbits, making a total of 63 satellites or 6 tons of payloads since its debut. Lots of missions are planned for the coming months. 2025 is going to be awesome." The Kinetica-1 is designed to place up to 2 metric tons of payload into low-Earth orbit. A larger liquid-fueled rocket, Kinetica-2, is scheduled to debut later this year. The Ars Technica Rocket Report The easiest way to keep up with Eric Berger's and Stephen Clark's reporting on all things space is to sign up for our newsletter. We'll collect their stories and deliver them straight to your inbox. Sign Me Up! French government backs a spaceplane startup. French spaceplane startup AndroMach announced May 15 that it received a contract from CNES, the French space agency, to begin testing an early prototype of its Banger v1 rocket engine, European Spaceflight reports. Founded in 2023, AndroMach is developing a pair of spaceplanes that will be used to perform suborbital and orbital missions to space. A suborbital spaceplane will utilize turbojet engines for horizontal takeoff and landing, and a pressure-fed biopropane/liquid oxygen rocket engine to reach space. Test flights of this smaller vehicle will begin in early 2027. A risky proposition ... A larger ÉTOILE "orbital shuttle" is designed to be launched by various small launch vehicles and will be capable of carrying payloads of up to 100 kilograms (220 pounds). According to the company, initial test flights of ÉTOILE are expected to begin at the beginning of the next decade. It's unclear how much CNES is committing to AndroMach through this contract, but the company says the funding will support testing of an early demonstrator for its propane-fueled engine, with a focus on evaluating its thermodynamic performance. It's good to see European governments supporting developments in commercial space, but the path to a small commercial orbital spaceplane is rife with risk. (submitted by EllPeaTea) Dawn Aerospace is taking orders. Another spaceplane company in a more advanced stage of development says it is now taking customer orders for flights to the edge of space. New Zealand-based Dawn Aerospace said it is beginning to take orders for its remotely piloted, rocket-powered suborbital spaceplane, known as Aurora, with first deliveries expected in 2027, Aviation Week & Space Technology reports. "This marks a historic milestone: the first time a space-capable vehicle—designed to fly beyond the Kármán line (100 kilometers or 328,000 feet)—has been offered for direct sale to customers," Dawn Aerospace said in a statement. While it hasn't yet reached space, Dawn's Aurora spaceplane flew to supersonic speed for the first time last year and climbed to an altitude of 82,500 feet (25.1 kilometers), setting a record for the fastest climb from a runway to 20 kilometers. Further along ... Aurora is small in stature, measuring just 15.7 feet (4.8 meters) long. It's designed to loft a payload of up to 22 pounds (10 kilograms) above the Kármán line for up to three minutes of microgravity, before returning to a runway landing. Eventually, Dawn wants to reduce the turnaround time between Aurora flights to less than four hours. "Aurora is set to become the fastest and highest-flying aircraft ever to take off from a conventional runway, blending the extreme performance of rocket propulsion with the reusability and operational simplicity of traditional aviation," Dawn said. The company's business model is akin to commercial airlines, where operators can purchase an aircraft directly from a manufacturer and manage their own operations. (submitted by EllPeaTea) India's workhorse rocket falls short of orbit. In a rare setback, Indian Space Research Organisation's (ISRO) launch vehicle PSLV-C61 malfunctioned and failed to place a surveillance satellite into the intended orbit last weekend, the Times of India reported. The Polar Satellite Launch Vehicle lifted off from a launch pad on the southeastern coast of India early Sunday, local time, with a radar reconnaissance satellite named EOS-09, or RISAT-1B. The satellite was likely intended to gather intelligence for the Indian military. "The country's military space capabilities, already hindered by developmental challenges, have suffered another setback with the loss of a potential strategic asset," the Times of India wrote. What happened? ... V. Narayanan, ISRO's chairman, later said that the rocket’s performance was normal until the third stage. The PSLV's third stage, powered by a solid rocket motor, suffered a "fall in chamber pressure" and the mission could not be accomplished, Narayanan said. Investigators are probing the root cause of the failure. Telemetry data indicated the rocket deviated from its planned flight path around six minutes after launch, when it was traveling more than 12,600 mph (5.66 kilometers per second), well short of the speed it needed to reach orbital velocity. The rocket and its payload fell into the Indian Ocean south of the launch site. This was the first PSLV launch failure in eight years, ending a streak of 21 consecutive successful flights. (submitted by EllPeaTea) SES makes a booking with Impulse Space. SES, owner of the world's largest fleet of geostationary satellites, plans to use Impulse Space’s Helios kick stage to take advantage of lower-cost, low-Earth-orbit (LEO) launch vehicles and get its satellites quickly into higher orbits, Aviation Week & Space Technology reports. SES hopes the combination will break a traditional launch conundrum for operators of medium-Earth-orbit (MEO) and geostationary orbit (GEO). These operators often must make a trade-off between a lower-cost launch that puts them farther from their satellite's final orbit, or a more expensive launch that can expedite their satellite's entry into service. A matter of hours ... On Thursday, SES and Impulse Space announced a multi-launch agreement to use the methane-fueled Helios kick stage. "The first mission, currently planned for 2027, will feature a dedicated deployment from a medium-lift launcher in LEO, followed by Helios transferring the 4-ton-class payload directly to GEO within eight hours of launch," Impulse said in a statement. Typically, this transit to GEO takes several weeks to several months, depending on the satellite's propulsion system. "Today, we’re not only partnering with Impulse to bring our satellites faster to orbit, but this will also allow us to extend their lifetime and accelerate service delivery to our customers," said Adel Al-Saleh, CEO of SES. "We're proud to become Helios' first dedicated commercial mission." Unpacking China's spaceflight patches. There's a fascinating set of new patches Chinese officials released for a series of launches with top-secret satellites over the last two months, Ars reports. These four patches depict Buddhist gods with a sense of artistry and sharp colors that stand apart from China's previous spaceflight emblems, and perhaps—or perhaps not—they can tell us something about the nature of the missions they represent. The missions launched so-called TJS satellites toward geostationary orbit, where they most likely will perform missions in surveillance, signals intelligence, or missile warning.  Making connections ... It's not difficult to start making connections between the Four Heavenly Gods and the missions that China's TJS satellites likely carry out in space. A protector with an umbrella? An all-seeing entity? This sounds like a possible link to spy craft or missile warning, but there's a chance Chinese officials approved the patches to misdirect outside observers, or there's no connection at all. China aims for an asteroid. China is set to launch its second Tianwen deep space exploration mission late May, targeting both a near-Earth asteroid and a main belt comet, Space News reports. The robotic Tianwen-2 spacecraft is being integrated with a Long March 3B rocket at the Xichang Satellite Launch Center in southwest China, the country's top state-owned aerospace contractor said. Airspace closure notices indicate a four-hour-long launch window opening at noon EDT (16:00–20:00 UTC) on May 28. Backup launch windows are scheduled for May 29 and 30. New frontiers ... Tianwen-2's first goal is to collect samples from a near-Earth asteroid designated 469219 Kamoʻoalewa, or 2016 HO3, and return them to Earth in late 2027 with a reentry module. The Tianwen-2 mothership will then set a course toward a comet for a secondary mission. This will be China's first sample return mission from beyond the Moon. The asteroid selected as the target for Tianwen-2 is believed by scientists to be less than 100 meters, or 330 feet, in diameter, and may be made of material thrown off the Moon some time in its ancient past. Results from Tianwen-2 may confirm that hypothesis. (submitted by EllPeaTea) Upgraded methalox rocket flies from Jiuquan. Another one of China's privately funded launch companies achieved a milestone this week. Landspace launched an upgraded version of its Zhuque-2E rocket Saturday from the Jiuquan launch base in northwestern China, Space News reports. The rocket delivered six satellites to orbit for a range of remote sensing, Earth observation, and technology demonstration missions. The Zhuque-2E is an improved version of the Zhuque-2, which became the first liquid methane-fueled rocket in the world to reach orbit in 2023. Larger envelope ... This was the second flight of the Zhuque-2E rocket design, but the first to utilize a wider payload fairing to provide more volume for satellites on their ride into space. The Zhuque-2E is a stepping stone toward a much larger rocket Landspace is developing called the Zhuque-3, a stainless steel launcher with a reusable first stage booster that, at least outwardly, bears some similarities to SpaceX's Falcon 9. (submitted by EllPeaTea) FAA clears SpaceX for Starship Flight 9. The Federal Aviation Administration gave the green light Thursday for SpaceX to launch the next test flight of its Starship mega-rocket as soon as next week, following two consecutive failures earlier this year, Ars reports. The failures set back SpaceX's Starship program by several months. The company aims to get the rocket's development back on track with the upcoming launch, Starship's ninth full-scale test flight since its debut in April 2023. Starship is central to SpaceX's long-held ambition to send humans to Mars and is the vehicle NASA has selected to land astronauts on the Moon under the umbrella of the government's Artemis program. Targeting Tuesday, for now ... In a statement Thursday, the FAA said SpaceX is authorized to launch the next Starship test flight, known as Flight 9, after finding the company "meets all of the rigorous safety, environmental and other licensing requirements." SpaceX has not confirmed a target launch date for the next launch of Starship, but warning notices for pilots and mariners to steer clear of hazard areas in the Gulf of Mexico suggest the flight might happen as soon as the evening of Tuesday, May 27. The rocket will lift off from Starbase, Texas, SpaceX's privately owned spaceport near the US-Mexico border. The FAA's approval comes with some stipulations, including that the launch must occur during "non-peak" times for air traffic and a larger closure of airspace downrange from Starbase. Space Force is fed up with Vulcan delays. In recent written testimony to a US House of Representatives subcommittee that oversees the military, the senior official responsible for purchasing launches for national security missions blistered one of the country's two primary rocket providers, Ars reports. The remarks from Major General Stephen G. Purdy, acting assistant secretary of the Air Force for Space Acquisition and Integration, concerned United Launch Alliance and its long-delayed development of the large Vulcan rocket. "The ULA Vulcan program has performed unsatisfactorily this past year," Purdy said in written testimony during a May 14 hearing before the House Armed Services Committee's Subcommittee on Strategic Forces. This portion of his testimony did not come up during the hearing, and it has not been reported publicly to date. Repairing trust ... "Major issues with the Vulcan have overshadowed its successful certification resulting in delays to the launch of four national security missions," Purdy wrote. "Despite the retirement of highly successful Atlas and Delta launch vehicles, the transition to Vulcan has been slow and continues to impact the completion of Space Force mission objectives." It has widely been known in the space community that military officials, who supported Vulcan with development contracts for the rocket and its engines that exceeded $1 billion, have been unhappy with the pace of the rocket's development. It was originally due to launch in 2020. At the end of his written testimony, Purdy emphasized that he expected ULA to do better. As part of his job as the Service Acquisition Executive for Space (SAE), Purdy noted that he has been tasked to transform space acquisition and to become more innovative. "For these programs, the prime contractors must re-establish baselines, establish a culture of accountability, and repair trust deficit to prove to the SAE that they are adopting the acquisition principles necessary to deliver capabilities at speed, on cost and on schedule." SpaceX's growth on the West Coast. SpaceX is moving ahead with expansion plans at Vandenberg Space Force Base, California, that will double its West Coast launch cadence and enable Falcon Heavy rockets to fly from California, Spaceflight Now reports. Last week, the Department of the Air Force issued its Draft Environmental Impact Statement (EIS), which considers proposed modifications from SpaceX to Space Launch Complex 6 (SLC-6) at Vandenberg. These modifications will include changes to support launches of Falcon 9 and Falcon Heavy rockets, the construction of two new landing pads for Falcon boosters adjacent to SLC-6, the demolition of unneeded structures at SLC-6, and increasing SpaceX’s permitted launch cadence from Vandenberg from 50 launches to 100. Doubling the fun ... The transformation of SLC-6 would include quite a bit of overhaul. Its most recent tenant, United Launch Alliance, previously used it for Delta IV rockets from 2006 through its final launch in September 2022. The following year, the Space Force handed over the launch pad to SpaceX, which lacked a pad at Vandenberg capable of supporting Falcon Heavy missions. The estimated launch cadence between SpaceX’s existing Falcon 9 pad at Vandenberg, known as SLC-4E, and SLC-6 would be a 70-11 split for Falcon 9 rockets in 2026, with one Falcon Heavy at SLC-6, for a total of 82 launches. That would increase to a 70-25 Falcon 9 split in 2027 and 2028, with an estimated five Falcon Heavy launches in each of those years. (submitted by EllPeaTea) Next three launches May 23: Falcon 9 | Starlink 11-16 | Vandenberg Space Force Base, California | 20:36 UTC May 24: Falcon 9 | Starlink 12-22 | Cape Canaveral Space Force Station, Florida | 17:19 UTC May 27: Falcon 9 | Starlink 17-1 | Vandenberg Space Force Base, California | 16:14 UTC Stephen Clark Space Reporter Stephen Clark Space Reporter Stephen Clark is a space reporter at Ars Technica, covering private space companies and the world’s space agencies. Stephen writes about the nexus of technology, science, policy, and business on and off the planet. 7 Comments

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.

Scientists have discovered a previously unknown bacterium aboard China's Tiangong space station. "It has been named Niallia tiangongensis, and it inhabited the cockpit controls on the station, living in microgravity conditions," reports Wired. From the report: According to China Central Television, the country's national broadcaster, taikonauts (Chinese astronauts) collected swab samples from the space station in May 2023, which were then frozen and sent back to Earth for study. The aim of this work was to investigate the behavior of microorganisms, gathered from a completely sealed environment with a human crew, during space travel, as part of the China Space Station Habitation Area Microbiome Program (CHAMP). A paper published in the Journal of Systematic and Evolutionary Microbiology describes how analysis of samples from the space station revealed this previously unseen bacterial species, which belongs to the genus Niallia. Genomic sequencing showed that its closest terrestrial relative is the bacterium Niallia circulans, although the Tiangong species has substantial genetic differences. [...] It is unclear whether the newly discovered microbe evolved on the space station or whether it is part of the vast sea of as yet unidentified microorganisms on Earth. To date, tens of thousands of bacterial species have been cataloged, although there are estimated to be billions more unclassified species on Earth. The discovery of Niallia tiangongensis will provide a better understanding of the microscopic hazards that the next generation of space travelers will face and help design sanitation protocols for extended missions. It is still too early to determine whether the space bacterium poses any danger to taikonauts aboard Tiangong, although it is known that its terrestrial relative, Niallia circulans, can cause sepsis, especially in immunocompromised people. Read more of this story at Slashdot.