World’s First Metal 3D Printer for Space Successfully Deposits Liquefied Test Lines Inside ESA Research Module

A small s-curve deposited in liquefied stainless steel demonstrates a huge leap forward for in-orbit manufacturing.

Metal 3D Printing in Orbit

On May 30, the very first metal 3D printing aboard the International Space Station (ISS) took place at the Columbus laboratory module of the European Space Station (ESA). The printer successfully dribbled out a molten "S curve," a game changer in 3D additive manufacturing in space.

According to ESA technical officer Rob Postema, the completed S-curve is a test line which ends the commissioning of their Metal 3D Printer. The technology demonstrator was developed under contract to ESA's Directorate of Human and Robotic Exploration. Meanwhile, the industrial team is led by Airbus Defense, ESA team and Space SAS.

Four shapes were chosen for full-scale 3D printing. The output will be returned to Earth to be compared with reference prints made in normal gravity. The project was advised by ESA materials engineer Advenit Makaya from the Directorate of Technology, Engineering and Quality.

Two of the printed parts will be analyzed in the Materials and Electrical Components Laboratory at Europe Space Research and Technology Centre (ESTEC) in the Netherlands. The other two will be brought to the Technical University of Denmark and the European Astronaut Center.

On January 31, the device reached the International Space Station through the Cygnus NG-20 resupply mission. The 399-pound (180-kilogram) payload was installed by ESA astronaut Andreas Mogensen in the European Draw Rack Mark II which is part of ESA's Columbus module.

The design of the printer is based on stainless steel wire fed into the printing area and heated by a high-power laser. As the wire is dipped into the melt pool, the end of the wire melts, adding the metal to the print.

The process of 3D printing the metal in orbit is entirely overseen from the ground at the CADMOS User Support Center in France. The onboard crew just has to open a nitrogen and venting valve before the printing begins. The printer operates within a fully sealed box to prevent the escape of excess heat or fumes.

Advancing In-Orbit Manufacturing

The project aims to understand the effect of microgravity on the process of printing metallic materials. Along with other reference lines, the success of the first print leaves the team ready to print full parts in the near future.

One of the goals of ESA is the creation of a circular space economy and recycling of materials in orbit. This enables better utilization of resources like repurposing items from worn out satellites into new structures or tools.

In the future, scientists plan to make an operational version of the metal 3D printer. By doing so, there will be no need to launch a tool with a rocket since the astronauts will be the one to print the needed materials in orbit.

Space printing can support future human explorations while contributing to more sustainable missions. As the technology demonstration shows how metals can be processed in microgravity, it can unlock future projects of manufacturing infrastructures outside the Earth.