Layered Solutions for Living Systems: Additive Manufacturing in Space Biology Hardware

Kurzfassung

In the face of extended human presence in space, understanding the biological impact of microgravity and cosmic radiation is essential. To address this, we at the Aeromedical FabLab (German Aerospace Center, DLR) develop modular, flight-proven hardware that bridges complex biological demands with practical aerospace constraints. This work presents a layered approach to hardware development, leveraging additive manufacturing (AM) as a key enabler for rapid iteration, modularity, and cost-effective customization. Using standard FDM and SLA 3D printing methods, we fabricate sterilizable, biocompatible reaction chambers, clinostats for simulated microgravity, parabolic flight racks, and robust payload modules for sounding rockets. By combining simple, open designs with agile prototyping, we achieve high adaptability — essential in a field where biological questions evolve faster than conventional hardware cycles allow. We demonstrate this flexibility through real-world case studies, including the MiniFix and ROMS payloads, highlighting how AM enables last-minute modifications, mission-specific optimizations, and even sustainability through compostable materials. This work argues that additive manufacturing democratizes access to complex space biology hardware: no cleanrooms, no heavy infrastructure, but rapid, precise, and mission-proven results. Ultimately, we show how AM shortens the distance between idea and flight, providing a robust toolset to safeguard life where it was never meant to exist — and to push the frontiers of human exploration, one printed layer at a time.