Additive manufacturing is already widely used in the space industry since it helps efficiently create parts and their prototypes that can withstand high temperatures and pressure, all at lower cost and in less time. These parts are then used in aerospace construction or sent to crews for mission needs. However, this technology has advanced even further – now people can 3D-print objects directly in space.

In-space printing allows us to reduce dependency on Earth’s supply chain by producing high-quality parts while cutting time, resources, and payload costs. This will enable future missions during which the crew will have little or no ability to receive resupply from Earth. Additionally, this form of production allows the use of in situ materials – both of terrestrial origin and those found on other planets, such as regolith – eliminating the need to transport raw materials. And while recycling materials may not save much money on short-duration missions, it becomes crucial for longer ones. Another benefit of this technology is the experience gained from printing in harsh conditions, which helps improve technological processes on Earth, since many printed parts are carefully studied and compared with Earth-made counterparts.

The first object to be printed in space was the printhead faceplate, produced on November 24, 2014, using fused filament fabrication with plastic. The next day, the first tool – a ratchet wrench – was printed. This was achieved through collaboration between NASA and Made In Space Inc. In February 2015, the first printed objects were brought back to Earth and analyzed using identical models printed on the ground. In 2024, the European Space Agency successfully achieved the first-ever 3D printing in space using metal. On June 8 of the same year, SpaceCAL (short for Space-Computed Axial Lithography 3D printer), created by a team of UC Berkeley researchers led by PhD student Taylor Waddell, was launched into suborbital space for a 140-second test flight (Isaac, 2023). This printer automatically detected zero gravity and used light to form objects from viscous plastic liquid inside four spinning vials, simultaneously creating multiple models which were then post-processed and cured.

Microgravity bioprinting is also rapidly developing. In 2016, the first cardiac and vascular tissues were printed using a bioink-based nScrypt bioprinter designed for zero-gravity use. From there, the company Techshot began developing specialized bioprinters for the ISS. In 2018, 3D Bioprinting Solutions successfully created a mouse thyroid on the International Space Station using a magnetic bioprinter. The BioFabrication Facility, developed and produced by Techshot, was delivered and installed on the ISS in 2019. On Earth, bioprinting faces challenges such as gravity effects and magnetic field interference, but in-space printing helps overcome these problems, allowing scientists to improve bioprinting technologies for regenerative medicine both on Earth and in space.

In space, several factors must be considered to ensure a successful printing process. Zero gravity creates adhesion problems, requiring strict control over the layering process. There are also challenges with heat distribution, extrusion, and the unpredictable behavior of liquid and molten materials. Moreover, the printer must be designed to withstand harsh conditions – radiation, vacuum environments, and possible turbulence – while being capable of operating for long periods without repair (3Dnatives, 2024). In addition, if the printed parts are used for mission needs, they must meet high standards of quality and reliability.

Future 3D printing in space is moving toward printers capable of using multiple materials simultaneously, allowing for the creation of complex, functional components in a single process. Scientists are developing new materials that can endure extreme space conditions such as radiation and temperature fluctuations, while remaining lightweight and durable. At the same time, improvements in printing processes and logistics aim to make manufacturing in orbit faster, more efficient, and less dependent on Earth’s resources. These advancements will enable astronauts to produce tools, parts, and structures directly in space, supporting long-term missions and future colonization efforts.

References:

1. NASA. (2014, December 1). Open for business: 3-D printer creates first object in space on International Space Station [Web article]. Retrieved from https://www.nasa.gov/missions/station/open-for-business-3-d-printer-creates-first-object-in-space-on-international-space-station/
2. NASA. (2015, April 20). 3D printing: Saving weight and space at launch [Web article]. Retrieved from https://www.nasa.gov/missions/station/iss-research/3d-printing-saving-weight-and-space-at-launch/
3. Isaac, B. (2023, June 5). A complete guide to zero gravity 3D printing [Web article]. 3Dnatives. Retrieved from https://www.3dnatives.com/en/a-complete-guide-to-zero-gravity-3d-printing/
4. 3Dnatives. (2024, May 7). UC Berkeley’s SpaceCAL 3D printer demonstrates success in orbit [Web article]. Retrieved from https://www.3dnatives.com/en/uc-berkeleys-spacecal-3d-printer-demonstrates-success-in-orbit-050720245/
5. NASA. (2015, April). Additive manufacturing: A summary of NASA research and technology development activities [PDF document]. Retrieved from https://www.nasa.gov/wp-content/uploads/2015/04/additive_mfg.pdf
6. NASA. (2019, August 27). 3D bioprinting in space [Web article]. Retrieved from https://www.nasa.gov/missions/station/iss-research/3d-bioprinting/