Astronauts 3D-print first metal part while on ISS | Space

ESA scientists have successfully demonstrated 3D printing of a metal part in space for the first time.

3D printing in space poses challenges, as many methods rely on gravity to position materials during the printing process. This is because when creating metal structures, molten metal is often used as part of the filament, or printable medium. In space, its behavior can be unpredictable, which can result in poor-quality objects, as the filament might shift or be placed incorrectly due to the lack of gravitational forces.

Scientists therefore had to adapt to work under these challenging conditions, and the International Space Station provided the perfect setting. ESA’s metal 3D printer uses a stainless steel wire melted by a powerful laser that reaches 2,192°F (1200°C) to create its molten metal filament that gets deposited layer-by-layer to build out a desired shape.

Through painstaking tests carried out over several months, the team was finally able to adjust the printer to its microgravity environment, producing the first metal part in space this August 2024. The team plans to print two more objects, then all three will be brought back to Earth for quality analysis and future planning.

Related: Future moon astronauts may 3D-print their supplies using lunar minerals