Hook: The Adhesive that Got a Shot Into Space
Sticking something together is plain idea, but when you want to stick a hand‑made push‑button to a spacecraft hatch, you need more than a dab of tape. In a week on Build Mode, founder Capella Kerst talked about how her idea—an engineered gecko‑inspired adhesive—went from a prototype on the Startup Battlefield stage to a tested product on the International Space Station (ISS). The story is a blueprint for hardware founders: leverage research, iterate quickly, build strategic partnerships, and always think about where the product will ultimately end up. If you’re turning lab physics into a market‑ready hardware solution, this case study is a must‑read.
1. Rooted in Research: From Cornell to a Compliant Co‑Acrylate
Capella started as a PhD student in mechanical engineering at Cornell, studying micro‑adhesive mechanisms in living organisms. She noticed how gecko feet bind to surfaces through surface energy and conformational fit. Her hypothesis: a synthetic micro‑structured polymer could reproduce that performance while being chemically safe for space use.
Why start with research? The hard part of a hardware product is proving you can do what you claim. In a dedication of early runway capital, Capella purchased a precision micro‑etching system and began crafting thin films of polyacrylates. Each iteration was tested on a set of common ISS materials—an adhesive weavers’ fabric, aluminum alloy, and conductive polymers—under vacuum and thermal cycling.
Lesson for founders: validate the core science before you tackle design—a single breakthrough experiment can buy you external credibility.
2. Startup Battlefield to Einstein‑Level Funding
Armed with a working prototype, Capella entered Startup Battlefield at Columbia University. She presented a clear problem: a lack of reliable, residue‑free adhesion for equipment in microgravity. The audience was captivated by her simple yet elegant solution—micro‑pillar arrays that cling through van der Waals forces and can be cleaned without harsh chemicals.
After winning the $150,000 prize, she leveraged the exposure to secure series A funding—$2.2 million—amenable to scaling the manufacturing process. Investors were turned on by the dual pitch: a niche market in space with segmented overflow into planetary prototyping, robotics, and even consumer wearables that could use the same adhesive.
Actionable insight: Use a single, clear problem statement linked to a tangible use‑case across multiple sectors. That multiplier effect can attract not only capital but also strategic corporate partners.
Scaling the Micro‑Pillar Toolkit
- Implement a continuous roll‑to‑roll process to coat large panels.
- Automate pillar assembly with robotic placement to keep dimensions within ±10 µm.
- Add a modular dispenser system for easy field application by astronauts.
3. NASA’s “Risk‑Zero” Standard Meets GeCKo’s Patents
NASA’s 28‑day risk window for ISS modifications is unforgiving. GeCKo’s adhesive had to meet stringent commands: no outgassing, no contamination, and must not interfere with the ISS thermal balance. Capella worked with NASA’s Space Systems Integration (SSI) office at Goddard and negotiated a scientific partnership that granted her access to the Space Dust Chamber and Environmental Testing facility.
Within six months, the adhesive went through q‑testing—temperature swings from –25 °C to 70 °C, vacuum at 10–5 Torr, and UV exposure. The result: a 30‑fold increase in holding force compared to standard epoxy glues, and no residue after cleaning with isopropyl solution. NASA’s acceptance was a huge endorsement that opened the door to a real in‑flight test.
Build an internal validation team that can interpret industry standards early. When you know the test bed ahead of production, you avoid costly redesigns.
Key Compliance Steps
- Map out the product’s life cycle from material sourcing to disposal.
- Engage an independent lab for outgassing and particulate tests.
- Document every change with version control to meet ATCC 3353 audits.
4. From Panel to Living Module: Implementing on the ISS
In March 2025, the first flight test began on the ISS’s Columbus module. The adhesive was used to secure a smartphone‑integrated sensor array designed to sense cabin atmosphere. The mission team had a limited window: the adhesive had to bond under zero g and later survive depressurization during inspection.
Outcome: The adhesive maintained its integrity throughout the six‑month certification period, and the sensor array stayed in place during both passive & active tests. A real‑world success story, it was featured in NASA’s Engineering EA‑26 and nominated for the Astronautics Innovation Award.
This success illustrates a 3‑step pathway: mock‑up validation, flight qualification, and post‑flight data collection. Tripwire lessons from the ISS bench can be translated to any high‑reliability environment.
Post‑Flight Insights
- Analyze micro‑damage in the pillars to refine tooling.
- Publish detailed metrics (adhesive force, surface wear) for open‑source communities.
- Leverage user feedback into a new product iteration—sticky, but also magnetic for dual‑mode applications.
5. Turning the Sticky Product Into Market Momentum
After the ISS test, geCKo pivoted to a broader strategy. They launched a pre‑order program for robotics labs and for planetary exploration kits, offering a “take‑home” sample kit. The kits contain a 10 × 10 cm panel with embedded gecko pillars, along with a guide for field application under various gravities.
The marketing message pivots: “The adhesive that will let your robot climb walls in microgravity and in the field on Earth.” A simple tagline, but reference to astronaut use injects trust. On Pull‑Quot and Kickstarter analogs, the product hit 300% of its goal within the first 48 hours, illustrating the power of proven use‑case stories.
Capitalizing on a high‑profile success like an ISS test can create a narrative that cuts through noise. Leverage media outlets with science‑based credibility (e.g., SpaceNews, Wired) to highlight the test outcome before launch day.
Actionable Marketing Tips
- Create a microsite dedicated to the ISS testing footage.
- Host a live Q&A session with Capella and NASA engineers.
- Offer a free sample kit for research labs that publish peer‑reviewed findings.
Conclusion: Lessons for the Next Engineering Startup
GeCKo Materials turned an academic curiosity into a “sticky” solution that walked from the Startup Battlefield to the ISS. The journey showcases embedded research validation, rapid scaling, strict compliance, and community‑driven marketing. For founders, the take‑away isn’t just about making a good adhesive; it’s about building a clear problem‑solution narrative, leveraging strategic partners, and crafting data‑driven stories that cross markets.
Now, if you’re ready to climb the next mountain—whether in multiple micro‑gravities or on Earth’s surface—take the geCKo approach: start with solid science, apply rigorous testing, and tell a story that shows your product can survive the most demanding environments.
Ready to make your product stick where it matters most? Contact us to explore how you can prototype, test, and launch—both in ground labs and orbital flight test environments.