Introducing: Nebula Form, the Young Startup Bringing 3D Printing to Space

Bremen, a city well-known for its aeronautics and space industry, is now home to ESA BIC Northern Germany’s latest young startup – NebulaForm. Founded by Prof. Dr. Dr.-Ing. Yilmaz Uygun and Serkan Özkan, NebulaForm is at the forefront of using 3D printing technology to address the unique challenges of space exploration. With their expertise in logistics engineering, manufacturing technology, renewable energy, and electromechanics, they are poised to make significant contributions to the aeronautics and space industry. Speaking with Yilmaz Uygun, we learned more about who they are, what they do, and why their 3D printers will help change life in space.

Who is NebulaForm?
NebulaForm is the brainchild of two visionary researchers and scientists from Constructor University in Bremen. Their journey began with a series of collaborative projects focused on 3D printing.

“We work together and have been doing so for many years on projects centred around 3D printing,” explains Yilmaz Uygun.

The core team, built around lead engineer Serkan Özkan, quickly recognized the growing interest in large-scale 3D printing. Pilot projects revealed a clear market need for such services, particularly within the aeronautics and space industries.

Initially, their focus was not specifically on space. However, their extensive network within Bremen’s vibrant startup community and connections in the United States naturally steered them towards the aerospace sector. “It was serendipity,” says Uygun. “We have many contacts in the automotive industry but given that Bremen is a leading hub for space and space technologies, it wasn’t surprising that this industry came to the forefront of our minds.”

Prof. Dr. Dr.-Ing. Yilmaz Uygun (© NebulaForm)

Serkan Özkan (© NebulaForm)

Pushing the Boundaries of Zero Gravity
At the heart of NebulaForm’s mission is the ambition to leverage the world’s largest Delta-3D-printer for the space industry. This state-of-the-art printer boasts a printing range of up to 1.5 metres in radius and a height of up to three metres, allowing for the creation of large, complex structures. Their ultimate goal is to expand this capability to a staggering twenty-four cubic metres, providing unparalleled flexibility and efficiency in manufacturing components for space missions.

World-largest industrial Delta-Type 3D printer (© NebulaForm)

Discovering ESA BIC Northern Germany
The turning point for Nebula Form came when they learned about the ESA Business Incubation Centre (BIC) Northern Germany. “I don’t remember the exact event, but there was a startup gathering at Kraftwerk, organized by Starthaus,” recalls Uygun. Colleagues from Starthaus recommended ESA BIC Northern Germany, recognizing it as a perfect fit for NebulaForm’s ambitions.

ESA BIC Northern Germany provides not only additional financial support but also access to a vast network of industry experts and potential collaborators. “We really want to tap into the network that ESA has and we’re looking forward to participating in all the different events they are part of,” Uygun notes.

Overcoming Challenges in Space Manufacturing
Developing a 3D printer for use in space presents a unique set of challenges. One of the main obstacles is ensuring the printer can function effectively in zero gravity. Unlike traditional 3D printers that rely on gravity to build layer by layer, NebulaForm’s rotational 3D printer is designed to operate without the need for gravity. This innovative approach has attracted the interest of national space agencies, eager to test the technology on future space missions. “Our first step is to develop a small prototype, because of the payload,” explains Uygun. “We want to see if it works, under what circumstances it may work, and then we can easily scale this.”

Model of the rotary 3D printer to be tested in orbit (© NebulaForm)

While other space agencies have made strides in this area, NebulaForm aims to move beyond proof-of-concept to successfully printing actual objects while in orbit.

Up Ahead for NebulaForm
NebulaForm’s immediate goal is to complete the development of their rotational 3D printer and secure its inclusion in an upcoming space mission. “By Fall this year, we hope to have the first scaled prototype ready,” says Uygun. They plan to resume discussions with interested space agencies to finalize details for testing the printer in space. Success in these initial trials could pave the way for broader adoption of 3D printing technology in space missions, enabling on-demand manufacturing of components and reducing the need for costly and complex logistics.

In the long term, NebulaForm envisions their technology playing a crucial role in space exploration and settlement. The ability to manufacture parts and tools in space could significantly enhance the efficiency and sustainability of missions, from building space habitats to supporting long-duration stays on the Moon and Mars.

The Role of ESA BIC Northern Germany and the City of Space
Bremen’s status as a leading hub for space and aeronautics has been instrumental in NebulaForm’s development. The city’s ecosystem of research institutions, industry leaders, and supportive organizations provides a fertile ground for innovation. ESA BIC Northern Germany has been a cornerstone of NebulaForm’s journey, offering not only financial support but also invaluable mentorship and networking opportunities.

“ESA is one of the leading space organizations, not just in Germany, but also in Europe,” Uygun emphasizes. Being part of ESA BIC Northern Germany allows NebulaForm to tap into a wealth of knowledge and resources, accelerating their progress and enhancing their credibility in the industry.

A Bright Future
As NebulaForm continues to innovate and push the boundaries of 3D printing technology, their contributions to the aerospace industry hold promise for transformative advancements. Their pioneering work in developing 3D printers for zero-gravity environments addresses a critical need for space exploration, offering the potential to revolutionize how we manufacture and assemble components in space.

With the support of ESA BIC Northern Germany and the thriving aeronautics and space community in Bremen, NebulaForm is well-positioned to achieve its ambitious goals. Their journey from a collaborative research project to a leading startup in space manufacturing is a testament to the power of innovation, collaboration, and the relentless pursuit of excellence. As they prepare for the next phase of their journey, the world watches with anticipation, eager to see how NebulaForm will shape the future of space exploration.

Model of a large-scale cartesian-type 3D printer for space applications (© NebulaForm)

(© NebulaForm)

About ESA BIC Northern Germany

The Incubation Centre of the European Space Agency in Northern Germany (ESA BIC Northern Germany) is headquartered jointly with the Bremen aeronautics and space industries association at the Bremer Innovations- und Technologiezentrum BITZ as well as the Digihub Industry – two of the largest innovation and technology centres for high-tech companies and startups in the German federal state of Bremen. The ESA BIC Northern Germany brings new startup opportunities to the region and thus strengthens the aeronautics and space sector in the German federal state of Bremen. AVIASPACE BREMEN e.V. supports the incubatees with its network, public relations work and targeted coaching not only during the incubation period, but also afterwards as alumni. STARTHAUS Bremen & Bremerhaven is the central point of contact in the Bremen startup ecosystem and supports the startups on all issues relating to business development and financing. The ESA BIC Northern Germany is managed by Anwendungszentrum GmbH Oberpfaffenhofen (AZO), an international networking and branding company for the European space programmes that also manages ESA BIC Bavaria with three locations in southern Germany.

Since 2021, ESA BIC Northern Germany has also been offering its service to space-related startups in Schleswig-Holstein. The Technikzentrum Lübeck with GATEWAY49, AviaSpace Bremen and AZO jointly operate this extension of ESA BIC Northern Germany. As of June 2024, ESA BIC Northern Germany also offers its services to space-related startups in Mecklenburg-Western Pomerania. The Innovation Port Wismar with AviaSpace Bremen and AZO jointly operate this extension of ESA BIC Northern Germany. There are also plans to extend ESA BIC Northern Germany to the northern German federal states of Hamburg, Lower Saxony, and Berlin-Brandenburg.

Technical support of the ESA BIC Northern Germany, is offered by Fraunhofer IFAM, German Research Center for Artificial Intelligence DFKI, Alfred-Wegener Institute for Polar Research AWI, Bremen University, Center of Applied Space Technology and Microgravity ZARM, TH Lübeck, University Lübeck,  , Life Science Nord, Airbus Group, ArianeGroup, AES Aircraft Elektro/Elektronik System, Dräger, DSI Aerospace, Possehl, and OHB.