First metal 3D printing in space

This was the first time that metal had been 3D printed in space, following years of research and technological refinement. The experiment is part of a larger effort to enable astronauts to become more self-sufficient during long-term missions, such as those to the Moon or Mars.

The metal 3D printer used in the experiment was designed and developed by a collaboration between Cranfield University and Airbus, and it was launched to the ISS in January 2024. The main goal of the experiment is to understand how microgravity impacts the 3D printing process and the quality of metal parts produced in space. The success of this experiment shows the technical ability to print metal, and it is also a leap forward in the quest for mission autonomy – because astronauts will eventually need to produce their own tools and spare parts during missions that take them far from Earth​.

Future missions

As space missions push deeper into the solar system, the logistics of supplying spare parts and tools from Earth become more difficult. It can take months for supplies to arrive, which is impractical for long-duration missions. 3D printing, particularly with metal, offers a solution to this problem by enabling astronauts to manufacture components as needed, directly aboard their spacecraft or space station.

The August test, while small in scope, was the culmination of years of development. The metal 3D printer uses a wire-based system, in contrast to traditional powder-based metal printers used on Earth, which are impractical in microgravity. The wire is fed into a laser-powered head, which melts and shapes the material into the required form. This method was chosen for safety reasons, as managing loose metal powder in space would pose significant hazards​.

Analysis and potential

The printed components from the August experiment were recently returned to Earth and are now being analysed by European institutions, including ESA’s technical centre in the Netherlands and Cranfield University. The primary focus of this analysis is to assess how the microgravity environment affected the quality of the printed metal compared to Earth-based processes. This data contains important information for refining future printing algorithms and understanding how to replicate Earth’s manufacturing standards in space​.

This experiment also lays the foundation for future advancements in space manufacturing. While plastic 3D printing has been used on the ISS since 2014, metal printing is far more complex but also offers greater possibilities. The ability to produce high-strength metal components directly in space could eventually allow astronauts to manufacture larger and more robust structures, tools, and spare parts. This could drastically reduce the need for resupply missions from Earth, enhancing the feasibility of long-term space exploration​.

In the coming years, this technology could be crucial for missions to the Moon and Mars, where astronauts may need to construct habitats, repair equipment, or produce components from locally available resources, such as lunar regolith. The ability to print metal in space is one of the many technologies that could make humanity’s long-term presence in space more sustainable.

This achievement is a turning point in space exploration, and it provides a glimpse into a future where astronauts can be largely self-sufficient during missions, creating tools and equipment on demand, far from Earth's supply chain.

Image credit: ESA/NASA