German startup Orbital Matter successfully 3D printed a half-meter long beam out of a custom plastic material in the vacuum of space using its Replicator 2 satellite.
The system relies on ultraviolet-cured resin extrusions to build rigid structures in orbit, paving the way for in-space manufacturing of solar arrays and antennas.
How does a printer work in space?
Orbital Matter's small satellite, called Replicator 2, launched last summer on a SpaceX flight carrying four 3D printers. Each printer creates a rigid, cylindrical beam by pushing out a special resin-like material that hardens with ultraviolet light.
According to the company's CEO and co-founder, Jakub Stojek, the mission proves that structures can be built in space exactly to the size required for a mission. Orbital Matter is working with the European Space Agency and Thales Alenia, among others.
The test and next steps
Two of the printers were designed to develop a flexible solar panel, but a technical issue led to the failure of one of the printers. However, the beam that was successfully created did deploy the solar panel normally, providing significant proof that the idea can work in practice.
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The company, founded in 2022 and having raised three million dollars in funding, is preparing a new demonstration mission for 2028. The goal is to test a larger version of the printer on a larger satellite, aiming to produce five kilowatts of power.
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