Moon base and Gecko satellites

Latest check in the lab: The NanoFF satellite is now in space.

Gray, the futuristic dome of the moon base stands out against the dusty surface. Its three-meter-thick walls made of lunar regolith provide astronauts with safe protection from dangerous cosmic radiation and impacts from micrometeorites. In a future where the moon has become a busy outpost for humanity, fortified roads and stable landing sites extend around the permanent base. They enable the smooth operation of lunar vehicles, robots, and rockets without sinking into the thick layer of dust covering the moon. Huge parabolic antennas and solar panels, manufactured on-site using 3D printing from lunar regolith, supply energy to the base and ensure communication with Earth. Listening to Enrico Stoll, head of the Department of Spacecraft Engineering, feels like being in a science fiction film.

Replicated Moon Dust

The key to realizing this vision lies in lunar regolith, the dust covering the entire moon, on which Neil Armstrong left his famous footprint. "The regolith mainly consists of oxide compounds based on iron, titanium, silicon, aluminum, or magnesium, and potentially offers abundant material for the future moon base," explains Stoll. Since transporting one kilogram of material from Earth to the moon costs around one million euros, scientists at TU Berlin are researching how to process moon dust, which they have specially recreated. Currently, they are developing a 3D printing technology that should work under the extreme conditions on the moon. First laser experiments with the regolith simulant have already been conducted in a vacuum chamber and in a drop tower under lunar gravity.

By 2026, in collaboration with the Hannover Laser Center, a laser developed by TU Berlin in the "MoonRise" project is scheduled to land on the moon and perform the first 3D printing with real lunar regolith. "If the process is successful, robots sent to the moon in advance could collect moon dust and produce building materials for structures and roads, as well as carrier materials for solar panels and everyday objects like cups and plates," explains Stoll. The extraction and utilization of elements from moon dust is also an exciting prospect.

This includes obtaining oxygen or silicon from the oxide compounds, as well as extracting metals such as iron, titanium, or aluminum. Students in the department are also researching a method to heat moon regolith without lasers. They plan to develop a mobile process based on a Fresnel lens that concentrates sunlight on-site to heat and further process the moon dust.

Space Recycling

Another space vision from Stoll, which his team is already working on, is inspired by the adhesion mechanisms of geckos. In the future, mini-satellites should be able to attach to satellites needing repair to exchange batteries or replace solar panels. Defunct units could be pulled out of their orbit to burn up in the Earth's atmosphere. Equipped with a docking mechanism that mimics the micro-properties of gecko feet using synthetic "adhesive pads," TU satellites aim to address the growing problem of space debris by serving as garbage collectors and repair services. The current TU Berlin mission "NanoFF" is already testing how multiple small satellites can navigate precisely in formation flight to perform future maintenance and repairs in orbit.

In the long term, Enrico Stoll plans to deploy these mini-satellites for interplanetary missions, such as to Venus or Mars, to collect scientific data and promote more sustainable use of space. His department has ample experience: currently, the 30th TU Berlin satellite is in orbit, operated by the Spacecraft Engineering department itself — a unique achievement for a university worldwide.

Department of Spacecraft Engineering

The TU Department of Spacecraft Engineering trains system engineers for space missions. The research focuses on distributed space systems, lunar exploration, and the development of robotic capabilities for small satellites in orbit. For more information, visit the department's website.