From Tunneling to the Stars – How Elara Aerospace Is Advancing Suborbital Rocket Engineering in Europe

At this time, we decisively decided to significantly simplify the design, allowing it to achieve higher precision and tolerance control through machining. During the redesign process, we realized that we needed to find a partner capable of manufacturing high-precision prototype parts—so we chose Xometry.

Collaborating with Xometry allows us to concentrate more on our core R&D, saving substantial time and significantly boosting project efficiency.

We designed it with maximum strength-to-weight efficiency in mind, combining tight tolerances with complex geometry. Since producing a part this precise was beyond our in-house capabilities, we relied on external manufacturing to bring it to life. Working with Xometry’s digital manufacturing platform proved to be a practical solution. The ordering process was simple, and the part was delivered exactly to spec, which helped us stay on schedule and move forward with system integration.

We can’t imagine any other partner who could have been able to deliver the parts in time to allow us to launch the product and exhibit it at Formnext.

For the physical prototype, I selected Selective Laser Sintering (SLS) using PA12 nylon. This combination offered the durability and dimensional accuracy I needed, while being light enough to preserve the model’s integrity and strong enough to handle repeated use. I ordered the parts through Xometry’s on-demand manufacturing service, which allowed me to test my designs without investing in a printer or tooling—a crucial advantage when working with small volumes and evolving prototypes.

UCL Racing's Mars Rover team developed an airless flexible wheel for the European Rover Challenge, competing on a simulated Martian surface. With Xometry's SLS 3D printing and engineering feedback, they produced six wheels from EOS TPU 1301 (Shore 86A) with a radial honeycomb lattice structure. The final design meets 220mm diameter and 120N load requirements, featuring symmetric tread pattern and integrated motor mount.

With Xometry, we have found a manufacturing partner that supports our development philosophy. The ability to quickly and precisely order small batches of parts gives us the freedom to iteratively improve our robots. This flexibility is essential to our innovation process.

The transition to electric has been a steep learning curve, but what keeps us moving forward is our ability to adapt and to work closely as a team. Every mistake or setback becomes a lesson that makes us stronger. Even when continuity is difficult, with experienced members graduating and new ones joining, the project itself becomes the bridge, carrying knowledge and experience forward.

Our project brings biological thinking to a field it rarely touches: thermal engineering. We are developing a thermally conductive nanolayer that coats heat exchange surfaces to combat biofouling and the buildup of dust and sediment.

Mr. Liang explained that after upgrading his handlebar extensions, mainstream stock bike frames failed to deliver his ideal reach measurement, a critical riding parameter. Shifting the seat position to compensate would compromise pedaling efficiency and alter his entire bike‑fitting data set. Ultimately, he decided to design a custom reach base mount precisely engineered to match his biomechanical requirements.

We wanted to aim for 10 complete kits, which meant we needed 20 machined cell bodies in a short amount of time. This is where Xometry came in. We received the parts in time for the workshop and had no issues with their assembly on-site. The workshop was successful and went off without a hitch.

In the past, developing non-standard devices was always complicated by the issue of tolerance matching between externally purchased standard parts and custom-machined components. Xometry's one-stop solution perfectly solved this pain point: they not only handled the complex metal 3D printing and sourcing of components but also delivered a finished product that had undergone precision assembly and adjustment. What we received was a functionally ready component that met our precision requirements. This efficient and worry-free delivery experience is exactly what R&D personnel need.