Could in-space manufacturing be the future for space missions?

With rocket launches becoming cheaper, it’s tempting to think we can just send more hardware into orbit – but the real solution lies in creating smarter, larger, and more sustainable space ecosystems through in-space manufacturing.

Everything humanity has built so far has been constrained by Earth’s gravity. It might seem natural to build within these limits, but when we manufacture in orbit, the rules – and possibilities – completely change. In my work, I focus on 3D printing in space, which offers a radically different approach to designing and building systems for space missions.

Unconstrained by gravity

Traditionally, spacecraft must be designed to fit within the limited mass and volume of a rocket’s payload fairing, the protective cone that protects it against the pressure and heat of launching through the atmosphere. At the same time, it must also withstand the intense accelerations and vibrations of launch. 

In-orbit manufacturing will allow us to bypass these constraints entirely. Instead of optimising for launch, we can optimise systems for their mission, which may last decades. Without gravity’s constraints, structures such as large antenna or radar built off-Earth could be lighter, larger, and use materials more efficiently, delivering better performance and greater capability.

Combining in-space manufacturing with recycling has transformative potential. Imagine if spacecraft were refurbished every decade: it could extend their lifespans to a century, reducing the need for new launches. This vision aligns with a more sustainable future for space exploration, where waste is repurposed, and innovation continues without adding to orbital debris. By enabling a circular economy in orbit, we can redefine the future of space engineering, ensuring resource efficiency and environmental responsibility.

One of the biggest challenges we faced in our own programme of research was overcoming the limitations of existing 3D printing methods. Many types of 3D printer, including those using polymer filaments or resin, are prone to defects, failures, and inefficiency. For example, resin-based printing often traps gases that create internal defects, while filament-based systems are prone to tangling or breakage. Powder-based 3D printers, on the other hand, require complex containment systems to manage material flow, which are difficult to implement in microgravity.

To address these challenges, we have developed and patented a granular 3D printing material for microgravity. This method avoids the complexities of traditional systems by eliminating the need for spools, curing processes, and consumables. Instead, we use a purely mechanical system with anti-clogging mechanisms to transport feedstock efficiently. A second breakthrough was creating a technology that allows us to reload the 3D printer while it’s operating, eliminating interruptions and minimising failure risks.

Heightened senses: on board a parabolic flight

Testing these technologies in microgravity was a critical step in validating their potential. I’ve always been passionate about testing innovations in extreme conditions, and parabolic flight provided the perfect environment to do so.

I’ve done quite a bit of skydiving, so I thought parabolic flight would feel familiar. I couldn’t have been more wrong. Microgravity sharpens your senses, making everything feel more vivid. Astronauts training with us described how the heightened blood flow to the brain enhances perception, and I could feel it myself. Having worked on this experiment for years, I was hyper-focused during the first flights. The stakes were high, and every detail mattered. When our initial tests matched our best-case simulations, it was a massive relief.

Floating freely in microgravity, I felt a surreal connection to the physics that inspired my career. It was a reminder of why I pursued space engineering in the first place. As the tests progressed, I began to relax, appreciating the unique sensations of weightlessness and the opportunity to witness years of hard work come to life in real time.

Building on the success of these foundational technologies, the next step is to 3D print active systems – structures embedded with electronics. This step is critical for creating spacecraft that can evolve and adapt over time. We’ll begin by testing these techniques in ultra-vacuum environments on Earth before advancing to in-flight demonstrations.

A further cornerstone of our progress is the UK Space Agency’s Enabling Technology Program, led by our group in partnership with the UK Manufacturing Technology Centre, which is vital for both the technological and business sustainability of our work. This initiative not only supports the development of new materials and methods, but also ensures that safety, environmental responsibility, and economic feasibility are at the forefront. By rigorously testing materials in space-like conditions, we’re minimising risks associated with defects that could lead to structural failures or space debris. This program is paving the way for creating technologies that are not only innovative but also responsible.

Our vision is bold yet achievable: a future where in-space manufacturing transforms how we build, repair, and sustain our presence beyond Earth. This vision doesn’t just advance space exploration – it reshapes it entirely, creating opportunities for deeper interplanetary missions and fostering a sustainable presence in orbit.

***

🧬 Why we should be making cancer immunotherapy drugs in space too