There is a VERY good chance that you could find a freehub from another hub that would fit, but chances are ALSO equally good that the freehub in question will be the exact same item from the exact same supplier. Some companies make all the parts to a hub in-house, but they are very few and far between. Most are machining their own hubshells to fit existing bearings, freehubs and axles (which they buy from outside suppliers). There are companies you've never heard of that basically just make shit tons of different freehub designs for different customers in the industry. If you're wondering how I know this... I work in the bike industry as a wheel builder.
If you wanna pay a lot of money to a good machine shop I'm sure they could one-off you a high end freehub out of whatever kind of unobtanium you like, but unless that hub has sentimental value you're better off just going with the stock part or an completely different hub. You'll drive yourself crazy trying to find an aftermarket freehub upgrade.
I've never seen a DT star ratchet failure. I'm sure it happens, but it's gotta be pretty damn rare. If I was a big guy I'd only ride star ratchet hubs like DT350/240.