Take an inside look at the Caltech Center for Autonomous Systems and Technologies (CAST), where precision engineering, AI robotics, and industrial 3D printing come together to prototype the future of exploration, mobility, and autonomy.
Caltech CAST: Where Vision Becomes Technology
Few places on Earth have the same pedigree in aerospace innovation as Caltech. Home to the CAST Laboratory, Caltech has been a driver of scientific advancement since the WWII era, helping establish the foundation for modern aerospace and space travel. The lab’s legacy includes supporting the Moon landing and contributing to the evolution of the Jet Propulsion Laboratory (JPL).
Today, CAST operates as a multidisciplinary hub where autonomous vehicles, AI-powered drones, and next-gen delivery robots are imagined, built, and tested—all under one roof.
Caltech Revolutionizing Prototyping with the 22 IDEX 3D Printer
One of the most transformative tools in CAST’s arsenal is the 22 IDEX industrial 3D printer. This high-performance printer, known for its independent dual extrusion, high-temperature capabilities, and print precision, allows researchers to create robust, functional prototypes directly in the lab.
Up to 70% of the structural and mechanical parts of Caltech’s autonomous robots—including the famed M4 Morphabot—are made using the 22 IDEX, right down to the gears, brackets, and protective shells. These parts don’t just stay in the lab—they travel globally and into space.
Materials as Strong as the Mission
To match the complexity of CAST’s projects, the lab uses industrial-grade materials like carbon fiber-filled nylon (CF Nylon) and carbon fiber-reinforced PEEK. These polymers provide titanium-like strength and thermal resistance—ideal for flight systems, Mars rovers, and high-performance drones operating in extreme conditions.
Big Ideas Need Big Printers: Enter the Hylo
Complementing the 22 IDEX is the Hylo 3D printer, which features a larger build volume and a tightly controlled heated chamber. It’s used for large-format prints and components requiring exceptional accuracy and material integrity, enabling rapid production of mission-critical aerospace parts.
M4 Morphabot and STOR: AI on the Move
Among CAST’s breakthrough technologies is the M4 Morphabot—a robot that drives, crouches, flies, and autonomously chooses its mode of transport based on terrain. This is no off-the-shelf machine; it’s an AI-driven hybrid built for real-world testing, prototyped and assembled using CAST’s in-house 3D printing capability.
Its sibling, the STOR robot, addresses last-mile delivery. It autonomously lands, drives to your door, and delivers packages without human contact—another shining example of combining robotics, AI, and high-strength 3D-printed components.
The World’s Largest Indoor Fan Array
To simulate conditions these robots will face, CAST features the largest indoor flight and wind-testing facility in the world. With 2,600 programmable fans and 48 motion capture cameras, this space replicates Mars-like winds and urban turbulence to refine drone flight and AI navigation algorithms in a safe, controllable setting.
More than Prototypes: Field-Ready Results
The synergy of advanced prototyping tools like the 22 IDEX and CAST’s integrated research model has enabled a unique success: what’s built in the lab doesn’t stay there. These machines are deployed in places like Dubai, Abu Dhabi, and test sites worldwide—ready for real-world demonstrations and environmental missions.
A Legacy Backed by Einstein and Jet Propulsion
Caltech’s history includes luminaries like Einstein and partnerships with NASA’s Jet Propulsion Laboratory. With such a legacy, CAST continues to push boundaries—designing collapsible structures for space, refining AI drones, and shaping what tomorrow’s flight and mobility systems will look like.
Why It Matters
In today’s race toward autonomy, sustainability, and exploration, Caltech’s CAST Lab stands at the intersection of science and real-world application. With technologies like the 22 IDEX enabling fast, flexible, and durable prototyping, Caltech isn’t just thinking about the future—they’re building it.
For those tracking the frontiers of aerospace engineering, robotics, and industrial 3D printing, CAST is where it all comes together.