Picture: ESA-R. Moorkens O'Reilly
A metal component manufactured on the International Space Station (ISS) has returned to Earth for the first time. The printed part was manufactured using the metal 3D printing system developed by Airbus and partners, which has been located in the Columbus module of the ISS since January 2024. ESA astronaut Andreas Mogensen installed the system as part of his Huginn mission. The first test production, a curved structure in the shape of an “S”, was completed in June. The first fully-fledged component was produced in the summer, followed by another sample in December.
The sample now on Earth is being examined in the Materials and Electrical Components Laboratory of ESTEC (European Space Research and Technology Center). The aim is to analyze how the printing process in microgravity differs from production under terrestrial conditions. Another printed component will be handed over to the Technical University of Denmark (DTU) for further investigations.
Until now, only plastic parts have been produced on the ISS using the 3D printing process. The successful use of a metal 3D printer opens up a new perspective for self-sufficient manufacturing in space. As future missions will operate further away from Earth, additive manufacturing is becoming increasingly important. By producing spare parts and tools directly in orbit, dependence on costly supplies could be reduced and repairs carried out more efficiently.
The research results from the analysis of the samples should help to better understand process stability and material properties in space. In the long term, this could pave the way for an expanded use of 3D printing in space missions, particularly with regard to lunar and Mars missions, where local manufacturing technology will be crucial.
