Orbital Matter 3D-prints first rigid beam in space vacuum

A German startup, Orbital Matter, has successfully 3D-printed a half-meter long rigid beam in the vacuum of space. This milestone occurred aboard the company’s small satellite, Replicator 2, which was launched this summer as part of a SpaceX rideshare mission. Executives from Orbital Matter describe this achievement as a first for a free-flying spacecraft, marking a significant step toward the construction of larger structures in space.

The significance of this breakthrough is rooted in the increasing demands for future spacecraft. As the need for more electrical power and efficient heat dissipation grows—especially for orbital data centers—craft will need to be larger. However, these spacecraft must still fit within the confines of a rocket’s fairing during launch. The ability to construct structures in orbit could simplify the engineering challenges associated with power generation and thermal management.

Replicator 2 is equipped with four 3D printers capable of extruding coils of resin that are cured by ultraviolet light, a process likened to mixing cement and water. While two of these printers are designed to deploy a flexible solar array, an anomaly caused one to fail. Nevertheless, the successful deployment of the solar array using the other printer serves as an important proof of concept. Current large structures in space often rely on folding mechanisms, making in-orbit assembly a promising alternative.

With aspirations for larger constructs, Orbital Matter's engineers believe that 100-meter booms are feasible, significantly surpassing the 20-meter solar arrays used in SpaceX's Starlink V2 satellites. Co-founded in 2022, the company aims to continue its innovations in space manufacturing. Orbital Matter is already preparing for another demonstration mission, scheduled for launch in 2024, which could further validate their groundbreaking technology.