Screenshot 2025-08-18 162501
A research team at Leibniz University Hannover has, for the first time, tested a flexible method for 3D printing with metal powder under microgravity conditions. The aim of the work is to make additive manufacturing usable for space missions — for example, to repair components or produce spare parts directly on the Moon or Mars.
The main technical challenge lies in handling metal powders, which are difficult to control in zero gravity. In collaboration with Otto von Guericke University Magdeburg, the researchers managed to adapt laser metal deposition for this purpose. In this process, metal powder is melted by a laser and deposited layer by layer onto a substrate. This enables not only the production of new components but also the targeted repair of damaged surfaces — eliminating the need to transport replacement parts.
For the tests, the team used the Einstein Elevator at the Hannover Institute of Technology (HITec). This large-scale research facility makes it possible to simulate various gravitational conditions in a closed capsule — from the forces of a rocket launch to microgravity. The entire experimental setup, consisting of a powder feeding system and laser unit, was adapted to these conditions. Among the processed materials were titanium and nickel alloys, both widely used in aerospace.
In the next step, the researchers, in cooperation with the Laser Zentrum Hannover, plan to investigate lunar dust (regolith) as a raw material. If it proves possible to use this material in the additive process, essential supplies could one day be produced directly on the Moon.
The project “Additive Manufacturing in Microgravity Using Laser Metal Deposition” is funded by the German Research Foundation (DFG).