The European Space Agency (ESA) has reached a significant milestone in space manufacturing with the successful 3D printing of the first metal part in microgravity conditions aboard the International Space Station (ISS). The groundbreaking print was produced by ESA’s Metal 3D Printer, a technology demonstrator developed in collaboration with Airbus and its partners.

Details of the Historic Print

ESA astronaut Andreas Mogensen installed the Metal 3D Printer in the European Drawer Rack of the Columbus module on the ISS earlier this year, after its launch in January 2024 on the Cygnus NG-20 resupply mission. In August, following a series of commissioning tests and adjustments, the printer successfully created the first 3D metal shape in space.

The printer is set to produce a total of four metal parts during the experiment. These prints, each smaller than a soda can and weighing less than 250 grams, will be returned to Earth for extensive quality analysis. Two samples will be examined at ESA’s technical center in the Netherlands (ESTEC), one will be assessed at the European Astronaut Centre (EAC) in Cologne, Germany, and the final piece will be studied by the Technical University of Denmark (DTU).

Overcoming Challenges of Metal 3D Printing in Space

Printing with metal in space presents unique technical challenges compared to traditional plastic 3D printing. The Metal 3D Printer had to be significantly miniaturized to fit within the constraints of the ISS while still ensuring the safety of the crew and the station itself.

Key challenges included:

• Size Reduction: Shrinking a typically large metal 3D printer to fit within the dimensions of the ISS rack.
• Safety Considerations: Protecting the ISS environment from the high temperatures and potential contaminants involved in metal printing.
• Gravity Management: Utilizing wire-based printing technology to function effectively in microgravity conditions.

The ESA team addressed these challenges through careful design and rigorous testing, paving the way for this historic achievement.

Implications for Future Space Exploration

The successful demonstration of metal 3D printing in space marks a significant step forward in advancing in-orbit manufacturing capabilities. As space missions to the Moon and Mars become longer and more complex, the ability to produce parts, tools, and structures on-demand will be essential for mission autonomy and crew self-sufficiency.

Additive manufacturing in space offers several key benefits:

• Reduced Payload: 3D printing allows for the creation of single-piece components, reducing the need for multiple parts and fasteners, resulting in lighter payloads and lower launch costs.
• On-Demand Production: Astronauts can print necessary items as needed, reducing dependency on resupply missions and increasing mission flexibility.
• Recycling Potential: In the future, materials from old satellites or structures could potentially be recycled and repurposed using 3D printing technology.

ESA’s pioneering work in this field lays the foundation for future endeavors, such as constructing lunar habitats using local resources and establishing a sustainable human presence beyond Earth.

Next Steps and Analysis

The printed metal parts will undergo rigorous testing and analysis upon their return to Earth. Researchers will compare the space-printed objects with identical samples printed on the ground to assess the impact of microgravity on the printing process and the resulting material properties.

These findings will provide valuable insights into refining and improving metal 3D printing techniques for space applications. ESA’s successful demonstration marks the beginning of a new era in space manufacturing, opening up exciting possibilities for future exploration missions.

As ESA’s Head of the Mechanical Department, Tommaso Ghidini, states, “Metal 3D printing in space is a promising capability to support future exploration activities, but also beyond, to contribute to more sustainable space activities, through in-situ manufacturing, repair and perhaps recycling of space structures, for a wide range of applications.”

With this milestone achievement, ESA has taken a significant leap forward in advancing in-space manufacturing technologies, paving the way for a new paradigm in space exploration and utilization.