Title: 3D Steel Printing Takes Off on the International Space Station
On May 30, 2024, a groundbreaking achievement in manufacturing occurred as a 3D steel printer successfully printed its first steel component aboard the International Space Station (ISS). This milestone marks a significant leap for in-orbit manufacturing, showcasing the capabilities of additive manufacturing in space.
The printing took place in the European Space Agency’s (ESA) Columbus Laboratory module, where the printer created a small S-curve from liquefied stainless steel. Rob Postema, an ESA technical officer, remarked, “The success of this first print, along with other reference lines, leaves us ready to print full parts in the near future.”
While polymer-based 3D printers have been operational on the ISS for some time, metal printing poses greater challenges due to the high temperatures and powerful lasers required to melt the metal. The new stainless steel printer uses a wire fed into the printing area, which is heated by a laser approximately one million times more powerful than a standard laser pointer, allowing for precise metal shaping.
Developed by a consortium that includes Airbus Defence and Space, AddUp, Cranfield University, and Highftech Engineering, this 3D printer was funded by the ESA. The printer is housed in a sealed metal box to protect the ISS from the intense heat and laser environment, as the melting point for metal alloys used in this process exceeds 1,200°C.
Gravity management is another critical factor, which led to the choice of wire-based technology over powder systems that rely on gravity. The printer, roughly the size of a microwave oven, is operated remotely from the CADMOS User Support Centre in France, requiring only the opening of a nitrogen and venting valve by the ISS crew to begin the printing process.
To evaluate the stainless steel printer's capabilities in space, several predetermined shapes will be printed and returned to Earth for comparison against ground-based prints. This analysis will help scientists understand the effects of microgravity on the printing process and material properties.
The ESA aims to leverage the 3D stainless steel printer to foster a circular economy in space. By manufacturing necessary parts and tools directly in orbit, reliance on rocket deliveries from Earth can be reduced, ultimately extending the lifespan of space equipment and optimizing resource use.
“Metal 3D printing in space is a promising capability to support future exploration activities,” said Tommaso Ghidini, Head of the Mechanical Department at the ESA. “This technology will contribute to more sustainable space activities through in-situ manufacturing, repair, and potentially recycling of space structures.”
As the steel industry reaches new heights—both literally and figuratively—the potential for 3D printing in space opens up exciting possibilities for the future of space exploration and resource management.
