In a groundbreaking achievement, steel manufacturing has officially entered the space age. On May 30, 2024, a 3D metal printer aboard the International Space Station successfully printed its first steel component, revolutionizing in-orbit manufacturing capabilities. This historic event took place in the European Space Agency's Columbus Laboratory module, where the printer created a small s-curve from liquefied stainless steel, demonstrating that 3D steel additive manufacturing is possible in the microgravity environment of space.
ESA technical officer Rob Postema explained the significance of this achievement, stating that the s-curve was a test line that successfully concluded the commissioning of their metal 3D printer. This initial success, along with other reference lines, has paved the way for printing full parts in the near future. While polymer-based 3D printers have been operating on the ISS for some time, metal printing presented a greater challenge due to the higher temperatures and lasers required to melt the metal.
The 3D steel printer, developed by a consortium comprising Airbus Defence and Space, AddUp, Cranfield University, and Highftech Engineering, uses a unique process to create objects in space. A stainless-steel wire is fed into the printing area and heated by a high-powered laser, approximately a million times stronger than a standard laser pointer. As the wire melts, the stainless steel is printed into the desired form, layer by layer.
Safety was a primary concern in developing this technology for use on the ISS. Sébastien Girault, metal 3D printer system engineer at Airbus, explained that protecting the ISS from the aggressive printing environment caused by the laser and heat was initially problematic. To address this, the printer was enclosed in a sealed metal box, acting as a safe. The team also had to account for the high melting point of metal alloys, which can exceed 1,200°C, compared to around 200°C for plastic. This necessitated drastic thermal control measures.
Another crucial factor in the printer's design was gravity management. The team chose wire-based printing technology because the wire is independent of gravity, unlike powder-based systems that rely on gravity for material distribution. This innovation allows for more reliable printing in the microgravity environment of space.
The printer, roughly the size of a microwave oven, is remotely operated from Earth at the CADMOS User Support Centre in France. ISS crew members only need to open a nitrogen and venting valve to initiate the printing process. To evaluate the printer's capabilities, it will initially produce predetermined shapes that will be returned to Earth for comparison with identical prints made under normal gravity conditions. Scientists will analyze data from both space and Earth-based tests to understand how microgravity affects the printing process and the properties of the printed metal.
Looking to the future, the ESA plans to use this 3D stainless steel printer to help create a circular economy in space. Tommaso Ghidini, Head of the Mechanical Department at the ESA, emphasized the potential of metal 3D printing in space to support future exploration activities and contribute to more sustainable space operations. This technology could enable in-situ manufacturing, repair, and potentially recycling of space structures for a wide range of applications, including large infrastructure manufacturing and assembly in orbit, as well as long-term human settlement on other planets.
As this technology continues to develop, it promises to revolutionize space exploration and manufacturing. The ability to produce metal components in space could significantly reduce the need for costly resupply missions from Earth and enable more self-sufficient and sustainable space operations. This achievement marks a significant step forward in humanity's ability to live and work in space, opening up new possibilities for future space missions and potentially paving the way for permanent human presence beyond Earth.
