Did this message show up randomly while you were in the laboratory, or did it show up shortly after you used stairs or moved between z-levels in some other way?
From what I understand from the game, this sounds mostly like you switched z-levels, the game tried to let your npc follow you, but there wasn’t any free space for him, so it couldn’t spawn him.
If it just showed up really randomly…maybe he, by pure accident, stepped into a teleportation trap, that might have caused it too.