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3D Printing Is Going to Space

3D Printing Is Going to Space
The startup Made in Space is employing advanced 3D printing to build objects in orbit

If you’re a nerd like me, the image of a half-constructed, almost skeletal second Death Star from Return of the Jedi is permanently lodged in your brain as one of the most majestically ominous creations in all of cinema.
George Lucas’ vision of building massive superstructures directly in outer space is iconic, but it’s hardly the first of its kind. The idea of manufacturing whole spacecraft or space stations that never touch Earth, that are fabricated and assembled directly out in the void where they will be operating, is one of humanity’s oldest science fiction dreams, dating back to antiquity, before the genre of sci-fi as we know it was even invented.
But now, outer space manufacturing is about to become a reality, albeit at a much smaller scale than the Death Star. The real-life Florida startup Made in Space recently won a $73.7 million contract from NASA to use, over the next three years, what’s essentially an advanced space-grade 3D printer to print out wings for a spacecraft while it orbits Earth.
Made in Space is pursuing something altogether more ambitious: producing whole new pieces of working equipment from raw materials in outer space — and doing so in a matter of days.
“We’re focused on the industrialization of space and moving the means of production into space,” said Justin Kugler, vice president of advanced programs and concepts at Made in Space, in a phone interview with OneZero.
To be clear, humanity has already gotten fairly good at assembling stuff in space — connecting one craft or piece of equipment to another using specialized tools, computers, physics, and robotics. That’s how the International Space Station and orbital laboratories from China and Russia were all put together over the years. But Made in Space is pursuing something altogether more ambitious and trickier: actually producing whole new pieces of working equipment from raw materials in outer space—and doing so in a matter of days.
Made in Space was founded nearly a decade ago in Silicon Valley by a quartet of entrepreneurial dudes: Aaron Kemmer, Jason Dunn, Mike Chen, and Michael Snyder. They were all part of some of the first graduate studies programs offered by Singularity University, a “benefit corporation” focused on nurturing advanced technologies that will move humanity toward the technology singularity, started by entrepreneur Peter Diamandis and futurist Ray Kurzweil.
Fittingly, given its lofty origins, Made in Space’s ultimate goal is that its 3D-printing-like technology will eventually be used to construct entire space settlements, cities even, at relatively lower cost than would be possible if those same structures were built on the ground first and then launched into space. (You’re paying a lot more for rocket fuel in those cases.)
The way Kugler describes it, using Made in Space’s technology, you’ll be able to launch small spacecraft and satellites that, once in orbit, could autonomously create the kinds of equipment normally restricted to larger, heavier satellites, at least when limited to traditional, Earth-bound production processes.
“You’re talking tens of millions [of dollars] compared to hundreds of millions,” said Kugler, referring to the cost savings Made in Space is envisioning.
NASA, whose funding yo-yos quite dramatically year over year, obviously sees the appeal of the cost-savings aspect of Made in Space’s approach.
“The benefit to the taxpayer is more efficient and affordable spacecraft and space vehicle designs that are not overdesigned (for launch) and that do not require the hardware needed to deploy the spacecraft into a usable configuration,” said Dayna Ise, a program executive at NASA’s Space Technology Mission Directorate division, in an emailed statement.
That same Made in Space tech could and likely will be used to build space weaponry and battle stations — though hopefully not on the mass-destruction scale of the Death Star. Northrop Grumman — the aerospace and defense contractor that makes the Global Hawk military drone, among other weaponry — is one of Made in Space’s key business partners.
First, though, there needs to be a working proof-of-concept of the idea, which is coming soon.
In 2022 or shortly thereafter, a rocket made by the aptly named company Rocket Lab Electron will launch from New Zealand and release Made in Space’s smaller spacecraft, the Archinaut One, which is about the size of a small refrigerator that you’d see in a college student’s dorm room.
It’s a cylindrical craft with some complicated-looking equipment strapped to the side and two tiny solar arrays sprouting on opposite sides like square robotic bat wings. But the relatively benign appearance hides some groundbreaking technology onboard. Archinaut One will carry its own additive manufacturing facility.
Additive manufacturing refers to a wide range of technologies and building processes, among them 3D printing, that all share in common the ability to fabricate objects with relatively high precision by applying layers of material on top of one another, adding them together to form a more complex object.
Desktop 3D printers have been around for years, sold by the likes of MakerBot (a subsidiary of Stratasys) and XYZprinting.
Made in Space has already built a printer slightly larger than these desktop models. In 2014, the company launched it aboard a SpaceX Dragon commercial cargo vessel, which it sent, along with some mice, to the International Space Station.
That printer, which Made in Space called a zero-gravity printer, printed more than a dozen items and ended up serving as the basis for all of its subsequent technology. It was succeeded by Made in Space’s more advanced additive manufacturing facility printer (AMF printer), launched to the space station in 2016 and since used to print more than 100 different tools, including everything from specialized wrenches to finger splints for astronauts. (They’re prone to injuring their fingers on all the finicky equipment aboard the space station.)
Now Made in Space plans to take the success of that very same technology and run a variation of it outside of the space station—in the even more inhospitable vacuum of space, on the side of the free-flying Archinaut One spacecraft. After decoupling from the Rocket Lab rocket, the Archinaut One will enter low-earth orbit (LEO to space industry folks, defined by NASA as the first 100 to 200 miles of space above Earth’s surface) and begin circling our home planet more than 11 times per day.
A few days later, the Archinaut One will conduct the historic, first-ever free-flying additive manufacturing demonstration in space, using a spool of polymer filament to print two 32-foot-long (64 feet total) semirigid beams extending from either side of the spacecraft.
The beams will be much larger than those the Archinaut One could otherwise support if it were relying on traditional space assembly methods, such as bringing them folded up into space from Earth, and will be used to act as a kind of scaffolding for long solar arrays that extend outward. “Like Venetian blinds,” according to Kugler.
Robotic arms will weave the electrical junctions through the solar arrays and connect them back into the spacecraft, providing working power. And all of this will happen automatically, controlled by software algorithms, with humans overseeing it back on the ground in Texas and Florida.
“Space being a difficult and unusual medium is 90% of the challenge we face,” Kugler told OneZero.
Although Made in Space likes to brag that it doesn’t have any competition when it comes to its specific space-grade additive manufacturing systems, the commercial space industry at large is broadly focused on developing technologies to reduce the weight, cost, and time it takes to put craft into orbit and beyond.
SpaceX has its impressively successful Falcon reusable rockets, while other companies, including Virgin Galactic and Sierra Nevada, are working on private reusable space shuttle–type craft. Bigelow Aerospace, the company founded by billionaire hotel magnate and UFO aficionado Robert Bigelow, has launched an inflatable human habitat to the space station and proven that the concept — using fabric lighter than traditional spacecraft materials to construct tentlike rooms in orbit — is viable for reducing weight at launch and, therefore, rocket fuel and cost.
These companies all face the same challenges humanity has encountered since we first started shooting rockets up into the sky—namely, that beyond Earth’s atmosphere is an inhospitable environment for pretty much everything, even strong materials like metal and plastic.
There’s the strong force of gravity exerted on the payload of a rocket launch, then all the speed and motion to get objects into space, and once they get there, they typically move at thousands of miles per hour. The atmosphere also helps protect objects on Earth from a number of damaging space forces, like debris, cosmic radiation, and the more unfiltered radiation and heat of the sun. So, designing systems that work in space requires solving for problems in physics, math, chemistry, electromagnetism, thermodynamics, computation, and materials science, among other disciplines.
In many ways, space is fundamentally opposed to the kinds of finicky and delicate 3D-printing processes that companies have developed for Earth, with extremely precise and even fragile moving parts.
Fortunately for Made in Space, its employees have already managed to solve some of the fundamentals. The company says it prudently designed its zero-gravity additive manufacturing to work in a wide range of differing gravity environments, from “more than one G to negative G,” according to Kugler — that is, gravity both stronger and weaker than what’s felt on Earth’s surface.
“For the future of building deep-space transit vehicles that will take people to far-off destinations and land, this is vital technology.”
In fact, even though the Archinaut One demo will be the first of its kind, it may be easier in some ways to accomplish than Made in Space’s previous feat of putting a printer aboard the space station, where it was more prone to jostling and other interference (“perturbations,” as Kugler calls them) from the astronauts going about their tasks, such as running on the space station treadmill.
If the company can pull off this demo, what’s next?
“In the near term, we can directly apply the tech from the Archinaut One to making small satellites that have larger, more efficient solar arrays or larger, more efficient active arrays, like antennas, reflectors, laser arrays,” Kugler said.
Made in Space thinks that within a few years after that, it will be able to build solar collection stations that can beam power to other spacecraft or customers down on Earth.
NASA, for one, is bullish on using Made in Space’s technology to create human-crewed spacecraft. “The timeline depends on a variety of factors, but the in-space robotic manufacturing and assembly capability could be matured to this level within the next decade,” Ise said.
“For the future of building cities in space and deep-space transit vehicles that will take people to far-off destinations and land, this is vital technology,” Kugler went on. “We will need a couple of miracles between now and then, but it’s possible.”
Made in Space isn’t talking up the potential for its technology to be used in Death Star–like superweapons—or any smaller weapons, for that matter. But it is open to developing craft and technology that can be used by the U.S. military.
Asked about the possibility of using the technology for defense purposes, Made in Space spokesperson Austin Jordan provided the following statement via email: “Our vision is that Made in Space will continue to be a close partner to the U.S. government across both defense and civil organizations. As it relates to national security and defense, in-space assembly and manufacturing capabilities could address key national security space priorities, including improving asset resilience, enhancing satellite capabilities, and providing rapid-response equipment. I think innovative technology platforms like Archinaut One will open up the playbook for us to engage with various agencies within the defense community to incorporate these capabilities into future missions.”
It may take a while, but if Made in Space’s visions pan out at all close to how the company hopes, future generations may look at the Death Star scenes in Star Wars as more realistic — perhaps worryingly so — than George Lucas could have ever anticipated.

































