Orbital Matter demonstrates in-orbit 3D printing of structural beams

German aerospace startup Orbital Matter has successfully utilized a satellite to 3D-print a half-meter-long structural beam while in orbit. The mission, carried out by the Replicator 2 satellite, marks the first time a free-flying spacecraft has manufactured a rigid structure using an onboard additive manufacturing process involving resin and ultraviolet curing.

Current satellite design relies on origami-like folding mechanisms to pack large components, such as solar arrays, into rocket fairings during launch. By shifting manufacturing to orbit, engineers could potentially deploy significantly larger solar arrays or antennas that exceed the current constraints of launch vehicle volumes. This is particularly relevant for the future development of orbital data centers that require substantial power and thermal dissipation.

While one of the four printers aboard the satellite experienced a failure, the successful deployment of a solar array using the printed structure serves as a key proof of concept. The company, which is collaborating with the European Space Agency and Thales Alenia Space, is now preparing for a 2028 follow-up mission aimed at scaling the technology to support higher power output requirements.