DISCOVER TWO 3D PRINTING BREAKTHROUGHS FROM THE EUROPEAN SPACE AGENCY

This month our focus is on 3D printing in the aerospace sector, and we recently looked at Elon Musk’s use of the technology for SpaceX . Today we shine a light on another organisation leading the field in additive manufacturing in space exploration - the European Space Agency (ESA). 

The ESA has made two significant breakthroughs, harnessing the potential of additive manufacturing to both redefine a key component and transform in-space manufacturing. 

In November last year, the ESA announced it was using 3D printing technology to produce electromagnetic coils for space missions. Working in partnership with ZARM Technik AG in Germany, who developed a sophisticated end-to-end process using laser powder bed fusion 3D printing, the Agency has enhanced the design of coils, which are crucial in electric motors, magnetic bearings and magnetorquers used for satellite attitude control. 

The advanced technology allows for more intricate designs and efficient production methods, delivering cost savings and enhanced space hardware. This, in turn, can enhance launch efficiency and fuel economy. 

However, perhaps the most significant development from the ESA has been the installation of its first metal 3D printer on the International Space Station (ISS). This project - a world first in 3D printing metal parts – is part of the Cygnus NG-20 resupply mission and positions the ESA as a leader in exploring new manufacturing technologies in orbit. The printer’s operations will be remotely monitored and controlled from Earth, which means printing activities can continue without the need for continuous supervision on site.

It’s not been easy, of course. 3D metal printing poses unique technical challenges, including high temperatures and laser usage, which present inevitable safety risks to the crew and the integrity of the ISS. However, the rewards are incredibly exciting. Unlocking the potential of 3D printing on the ISS itself means those on board can benefit from increased strength, conductivity, and rigidity of new and replacement components, on demand. It may also support possible recycling of space structures, creating a circular space economy. 

Expect more advancements to come, but these two examples already demonstrate the ESA’s commitment to driving innovation through 3D printing technologies. We’ll be watching closely to see how else they implement additive manufacturing to enhance space exploration.   

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