In just 30 hours, the Photonic Fabricators team led by Manfred Ehresmann, a PhD candidate at the Institute of Space Systems at the University of Stuttgart, developed a concept for a powder-based laser 3D printer that can manufacture parts in orbit. The chosen material is intended to be recycled within a closed loop. The laser also enables cutting, engraving and post-processing of manufactured parts — thereby combining fabrication and finishing in a single system. The photo on the right shows an exemplary material sample during surface engraving.
Laser-based 3D printing for orbit convinces the jury
In just 30 hours, the Photonic Fabricators team led by Manfred Ehresmann, a PhD candidate at the Institute of Space Systems at the University of Stuttgart, developed a concept for a powder-based laser 3D printer that can manufacture parts in orbit. The chosen material is intended to be recycled within a closed loop. The laser also enables cutting, engraving and post-processing of manufactured parts — thereby combining fabrication and finishing in a single system. The photo on the right shows an exemplary material sample during surface engraving.
The approach aims to expand materials-science research opportunities for laser-based manufacturing aboard the planned Starlab space station. It also seeks to enable the production of spare parts independently of resupply deliveries, thereby reducing costly logistics. In the longer term, resources from the Moon, Mars or asteroids could even be used.
Motivated team
“We were well prepared, but sharpening our idea for a strong business perspective was demanding — and exciting,” said Manfred Ehresmann. He was particularly impressed by the teamwork: “It’s great to find a motivated team in a short time and to tinker, discuss and make progress together.”
Co-lead Yolantha Remane also highlighted the team dynamics: “It was great and at the same time stressful — coordinating a team with continuous, valuable input from experts is challenging but a lot of fun.”
Technical lead Johannes Wübbeling emphasized the complexity of the task: “Designing a powder-based 3D printer for use on a space station is challenging. The feedback we received during the hackathon allowed us to further refine the concept.”
Philip Kius was responsible for the four-minute pitch: “Compressing an idea made up of many interlocking elements so that it is also convincing economically is not easy — but a valuable experience.”
Leon Habermalz handled communications: “It was fun to underpin content with robust figures in a short time and to present it plausibly for a non-expert audience.”
From a research perspective, Bahar Karahan added: “There is currently a lot happening in space manufacturing — we are pleased that our approach goes beyond existing ideas and was well received.”
Jannis Bertling of UZH/ZHAW offered a personal conclusion: “As someone without a space background, I appreciated the insight into the engineering side — I could contribute my know-how meaningfully. The hackathon was a very pleasant event.”
Wide range of ideas in the final
The competition demonstrated the variety of possible Starlab applications: from external payload adapters and storage capacities to crew support systems, automated supply solutions and modular bio-platforms. Several submissions focused on materials research — from semiconductor crystal growth to experiments outside the space station. Entries were judged on criteria such as societal relevance, market potential, relevance to spaceflight, feasibility and team competence.
Background: Starlab and the hackathon
Starlab is a next-generation commercial space station scheduled for launch in 2028. With over 400 planned experiments per year, it aims to enable research, technology development and commercial applications in low Earth orbit. The hackathon connects technical, scientific and economic perspectives and prepares students to develop future technologies for Starlab.
Outlook
The second-place finish underlines the Photonic Fabricators team’s innovative strength and the growing importance of autonomous manufacturing systems in space. The group plans to further develop its concept, involve collaboration partners and lay the groundwork for future demonstrators. In the long term, the system could make a significant contribution to orbital supply security and enable the use of extraterrestrial raw materials — a building block for sustainable space missions of the future.
Links to news:
- Manfred Ehresmann (ehresmann@irs.uni-stuttgart.de)
Aerospace research at the University of Stuttgart Stuttgart aerospace is a nationally unique, interdisciplinary incubator for key technologies for space and Earth. Researchers at the University of Stuttgart combine expertise in climate and energy research, communication technology, propulsion systems and AI-based flight. A central focus is researching sustainable technological solutions to minimize the environmental impact of aviation and spaceflight. Research is conducted interdisciplinarily and in close dialogue with regional and international partners from academia and industry, for example within the collaborative research centers ATLAS (SFB 1667) and SynTrac (SFB-TRR 364). As a partner of THE Aerospace LÄND, the University of Stuttgart contributes to implementing the state of Baden-Württemberg’s strategy to make aerospace sustainable, digital and collaborative by 2050. The university offers its students a solid engineering and application-oriented education and cooperates in talent promotion with the “Zukunftsoffensive Luft- und Raumfahrt-Nachwuchs,” an initiative of the state of Baden-Württemberg that advocates strengthening Nachwuchsförderung in STEM fields.