From Mars rovers to flying ambulances, additive manufacturing at Caltech’s CASTx is rewriting the rules of aerospace design.
A New Frontier: 3D Printing for Planetary Infrastructure
Imagine sending robots to Mars not just to explore, but to build. At Caltech’s CASTx Laboratory, that’s more than a vision—it’s an active research initiative. Engineers are leveraging advanced 3D printing to develop autonomous systems capable of self-repair and infrastructure construction on other planets.
Inside CASTx: Where Engineering Disciplines Unite
CASTx thrives on multidisciplinary collaboration. Aerospace engineers, roboticists, geologists, and biologists converge in a shared lab to prototype systems designed for real-world space challenges. This collaborative ecosystem enables rapid development of solutions that consider not just mechanics, but planetary science and biology as well.
The Mars Helicopter & the Evolution of Flight Robotics
CASTx played a pivotal role in the success of the Mars Helicopter project—a collaboration with JPL that led to the first powered flight on another planet. Now, the lab is advancing with the M4 robot, a hybrid rover-flyer designed for aerial mobility on extraterrestrial terrains.
Why Additive Manufacturing Is a Game Changer
Before 3D printing, hardware design iterations were slow and costly. With additive manufacturing, CASTx can go from idea to functional prototype in a fraction of the time—about 20% of what traditional methods required. This pace empowers researchers to validate their ideas quickly and get credited for their innovations faster.
22 IDEX by Vision Miner: A Catalyst for Innovation
When it came to choosing the right 3D printer, CASTx turned to the 22 IDEX by Vision Miner. The machine’s large-volume, dual-extrusion system enables high-temperature material printing—especially critical when working with robust polymers like carbon-fiber PEEK.
From day one, Vision Miner provided expert support, helping the lab overcome common failure points with these advanced materials. This allowed for rapid adoption and integration into CASTx’s workflows—producing durable, functional components right out of the gate.
Pushing the Limits of Functional Plastics
Initial questions about the viability of 3D-printed parts in real-world applications have been resoundingly answered. CASTx now produces parts that can withstand high thrust, extreme temperatures, and physical stress—ideal for environments like Mars or deep space missions.
One standout project is an autonomous flying ambulance, built at 1/5 scale with lift thrusters and foldable wings. Nearly 90% of the vehicle was printed on the 22 IDEX, demonstrating the potential of large-format additive manufacturing to support both rapid prototyping and flight-ready production.
Why Material Science Matters
Advanced materials like carbon-fiber PEEK enable structures that are lightweight, high-strength, and thermally resilient—unlike traditional brittle plastics that warp under desert heat. The 22 IDEX’s high-temp capabilities made these breakthroughs possible.
Components like wheels, chassis, and motor mounts were all printed as monocoque assemblies, minimizing the need for fasteners and reducing overall weight. This approach ensures structural integrity while simplifying production and assembly.
Beyond Prototyping: Validated for Space
CASTx doesn’t just 3D print for fun—it’s a rigorous process backed by scientific validation. Every material is tested and quantified at a physics level to meet NASA, JPL, and academic research standards. Additive manufacturing has evolved into a primary tool for creating real-world mission-ready parts.
Conclusion: 3D Printing Is Here to Stay
The impact of 3D printing at Caltech’s CASTx is clear. What used to take years can now be done in a matter of months. From Mars conferences to robotics expos in Abu Dhabi, the lab’s 3D-printed robots are turning heads worldwide.
With support from companies like Vision Miner, the learning curve has flattened—and the results speak for themselves. The next wave of planetary exploration won’t just be fueled by rockets; it will be built layer by layer, one printed part at a time.
Interested in high-performance 3D printing for aerospace or robotics? Explore the capabilities of the 22 IDEX by Vision Miner—proven in one of the world’s most advanced research labs.