Orbital Matter 3D Prints First Rigid Beam in Space Vacuum from Free-Flying Satellite

First In-Orbit 3D Printing of Rigid Beam

German startup Orbital Matter announced that its Replicator 2 satellite successfully 3D printed a half-meter long rigid beam. This beam was created from a custom plastic material in the vacuum of space, marking the first time a free-flying spacecraft has achieved such a feat in orbit.

Technology and Process

The Replicator 2 satellite, launched on a SpaceX rideshare mission, carried four 3D printers. Each printer extrudes coils of resin, which are then cured by ultraviolet light to form rigid, cylindrical beams. This method allows for the construction of structures directly in space.

Addressing Spacecraft Size Limitations

The ability to construct structures in orbit addresses a key challenge for future spacecraft: the need for larger components for increased electrical power generation and heat dissipation, especially for concepts like orbital data centers. Current spacecraft are limited by the size constraints of rocket fairings, necessitating complex folding and deployment mechanisms. In-orbit manufacturing removes these size restrictions.

Proof of Concept and Future Implications

This successful demonstration validates the concept of building structures in space to meet mission demands. Orbital Matter is collaborating with the European Space Agency and Thales Alenia. While one of the printers designed for a flexible solar array experienced an anomaly, the created boom successfully deployed the array, further proving the technology's potential. Previous 3D printing in microgravity was confined to the pressurized environment of the International Space Station.