Xometry Powers AcubeSAT from Prototype to Launch‑Ready Nanosatellite

Earlier, we introduced the SpaceDot team from the Aristotle University of Thessaloniki and its ambitious AcubeSAT project. Now the team is advancing to a new phase, upgrading AcubeSAT into a fully functional nanosatellite laboratory capable of sustaining yeast cells in orbit. By overcoming new engineering challenges and collaborating openly via GitLab, the team continues to demonstrate how academic‑led projects drive innovation in space exploration.

Hello! We are SpaceDot, a non‑profit interdisciplinary student team from the Aristotle University of Thessaloniki, Greece. Our mission is to pioneer innovative space applications and unlock the potential of open‑source space research. Using open‑source tools across all our projects, we are committed to sharing research outcomes with the global community. All our work — including code, models, designs and documentation — is published on GitHub under open licences via the AcubeSAT GitLab page.

In our previous case story, we shared how we designed and built AcubeSAT, a 3U nanosatellite (30×10×10 cm) equipped with a biological payload for yeast‑cell experiments, pushing the boundaries of open‑source space biology. We detailed the challenges of building a system capable of studying more than 100 proteins under the extreme conditions of space. Following initial trials and testing, we are excited to announce that through process optimisation and overcoming new engineering hurdles, AcubeSAT is now one step closer to its final orbital mission.

AcubeSAT: A Modular Nanosatellite for Space‑Based Biological Research

A Miniature Microbial Laboratory in Space

Our solution is a modular, fully functional mini‑laboratory engineered not only to meet mission requirements but also to enable rapid expansion and component interchangeability.

To achieve this, we designed inflatable pressurised vessels, a fluid system that delivers nutrients to cells, an imaging system for growth monitoring, precision electronics that govern all functions, and other essential subsystems. Among all components, the fluid manifold serves as the critical core of the experiment.

AcubeSAT Carrier Component Rendering

Engineering a Reliable Fluid Manifold for Space Missions

Multiple experiments must be conducted in‑orbit to fully investigate the impacts of the space environment. This requires a component that precisely distributes and regulates nutrient fluid flow.

The team initially considered complex piping networks, yet their numerous potential failure points failed to meet space‑grade reliability standards. We therefore shifted to a manifold design: a lightweight, compact component with internal flow channels controlled by a single inlet and outlet to deliver continuous nutrition to cells.

Manufacturing capability and material selection are as vital as functionality and must be considered from the earliest design phase. To meet the manifold’s complex design requirements, we began experimenting with 3D printing. We first validated concepts using FDM printing, yet inter‑layer void defects made the process unsuitable for space applications. We then moved to SLA printing for superior precision and quality.

Fluid Manifold: Compact Design for Precise Nutrient Solution Flow Implementation on AcubeSAT

While initial results were promising, we soon discovered that this approach made proper assembly and leak‑proof sealing of numerous connectors extremely difficult, necessitating a full design revision.

At this point, we made the strategic decision to significantly simplify the design so it could be machined to achieve higher precision and tighter tolerance control. During the redesign phase, we recognised the need for a partner capable of manufacturing high‑fidelity prototypes — and chose Xometry.

Proof of Concept: Testing CNC‑Machined Prototypes

When we finally received our CNC‑machined aluminium prototype, the design was successfully brought to life. We immediately began rigorous testing to verify compliance with the project’s stringent requirements.

CNC machined prototype of a fluid manifold manufactured by Xometry Zemi Technology

Preliminary trials including valve assembly and fluid distribution testing validated the component’s strong potential. Although minor design adjustments were still required, we were confident we were moving in the right direction and that all efforts were worthwhile. Holding a physical component after months of digital design work is every engineer’s most rewarding milestone.

Entering the Final Phase of Environmental Qualification Testing

As the project advances rapidly, we look forward eagerly to upcoming milestones. Our next step is to subject the payload to extreme space‑environment qualification testing. Our design will undergo launch and in‑orbit simulation trials at ESA facilities in Belgium, which will ultimately verify its space compatibility and mission readiness.

With launch preparations now underway, we are thrilled to progress toward AcubeSAT’s planned mission. Wish us luck as we approach this pivotal moment!