The European Space Agency (ESA) has just reached a major milestone in on-orbit manufacturing with the first 3D printing of metal in space. This achievement could offer new prospects for the space industry and the creation of a circular economy in space.
On May 30, aboard the ESA Columbus laboratory module on the International Space Stationa metal 3D printer successfully deposited an S-curve in liquefied stainless steel.
Rob Postema, ESA technical manager, said: “The success of this first print, along with other baselines, has us ready to print full parts in the near future.»
Developed by an industrial team led by Airbus Defense and Space SAS, under contract with ESA’s Human and Robotic Exploration Directorate, the metal 3D printer was installed in January 2024 by ESA astronaut Andreas Mogensen.
An innovative and secure printing process
The metal 3D printer works by feeding the printing area with stainless steel wire, which is heated by a high power laser. When the end of the wire dips into the weld pool, it melts and adds metal to the print. The printing process is managed entirely from the ground, with the crew on board only needing to open a nitrogen and ventilation valve before printing begins.
For safety reasons, the printer operates in a fully sealed box, preventing excess heat or fumes from escaping.
Analysis of printed parts and future perspectives
Four shapes were chosen for large-scale 3D prints which will then be returned to Earth to be compared to reference prints made on the ground in normal gravity. Two of these printed parts will be analyzed at the ESTEC Electrical Materials and Components Laboratory in the Netherlands, to understand whether the prolonged microgravity has an effect on printing metal materials.
One of ESA’s future development goals is to create a circular space economy and recycle materials in orbit to enable better use of resources, such as reusing parts from old satellites to create new tools or structures.
A working version of this metal 3D printer would eliminate the need to send a tool with a rocket and allow astronauts to print necessary parts in orbit.
Illustration caption: First 3D printing of metal in space. Credit: ESA/Airbus.
