Laser Additive Manufacturing Launches into Space

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Published September 9, 2025

When a bracket breaks on Earth, it’s a quick fix. However, if that bracket holds part of a satellite together in orbit or supports equipment on a Mars rover, it’s not as simple. That’s why space and defense agencies, such as the US National Aeronautics and Space Administration (NASA), are looking for different options. One promising technology they’ve turned to is laser additive manufacturing (LAM). This encompasses several additive manufacturing processes, including more commonly used practices like powder bed fusion (PBF)—also known as selective laser melting (SLM)—which is a process that uses high-powered lasers to fuse metal powder into fully functional parts. In this week’s New Tech Tuesdays, we dig into how LAM is offering manufacturing solutions in environments where traditional manufacturing is impossible.

NASA’s in-space manufacturing initiative was one of the first programs that proved additive manufacturing (AM) in zero gravity was possible. Its first polymer printer, installed on the International Space Station (ISS) in 2014, proved that 3D printing could work in orbit (Figure 1). Since then, NASA and commercial partners like Redwire Space have been working to extend these capabilities to metal components.^[1]

Figure 1: The International Space Station’s 3D printer. (Source: NASA)^[2]

The European Space Agency (ESA) has taken things further with its Laser Additive Manufacturing Process (LAMP) project.^[3] These laser-based metal printing systems are suitable for space habitats and robotic exploration platforms. They can produce high-precision metal components like spacecraft brackets, tools, and antenna parts directly aboard orbiting platforms or even future deep-space habitats.

LAM is suited for these types of applications because it does not require cutting tools, can produce parts with little waste, and supports lightweight, topology-optimized designs, which is beneficial when payload weight is critical.

However, one challenge in space-based printing is powder flow. Without gravity, managing fine metal powders can be tricky. Engineers are experimenting with enclosed print chambers,^[4] gas flows, and electrostatic controls to keep materials positioned correctly during the laser fusing process.

Another issue is thermal regulation. Cooling printed parts on Earth is easier because there is airflow, but in space, engineers have to rely on conduction and radiation since there is no atmosphere to pull the heat away. This adds complexity to motion control and thermal management systems, which makes precision hardware necessary.

To make LAM possible, a variety of advanced technologies work together:

• High-power fiber lasers that generate the energy needed to melt metal powder accurately and consistently.
• Laser driver circuits that control the laser’s power output in real time and can adjust the intensity to match build conditions.
• Precision motion control systems that guide the laser or move the build platform to control the movement and alignment during printing (using galvanometers, linear actuators, or robotic arms).
• Environmental enclosures and gas control that keep metal powder contained and prevent oxidation.
• Cooling solutions that remove heat from printed parts using radiation, conduction, or thermoelectric coolers, which are all essential in vacuum conditions.

A critical constraint for LAM in space involves the resources for printing. In-situ resource utilization (ISRU) will play a role as we work toward lunar habitats and Mars missions. Instead of transporting building materials from Earth—which is not quite feasible— astronauts could use loose rock and dust found on the Moon’s surface, called lunar regolith, and turn it into printable material to print parts, tools, or even entire structures (Figure 2).^[5]

Figure 2: An environmental view of the patented and jointly developed 3D print head mechanism for ISRU in combination with a robotic arm. (Source: NASA)^[6]

Researchers are testing hybrid systems that combine sintering and laser melting to work with non-metallic regolith. They are also developing ruggedized LAM platforms that can operate in extreme temperatures and environments where abrasive dust is present.

One future-looking concept involves deploying orbital platforms equipped with robotic LAM arms that could manufacture and assemble satellite structures in free space. This would remove the need to launch fully assembled systems from Earth and open doors for a host of space exploration opportunities.

Laser additive manufacturing in harsh environments like space requires specialized hardware, such as Cinch Dura-Con^™ Space Screened Micro-D cable assemblies. These assemblies meet or surpass MIL-DTL-83513 and NASA’s EEE-INST-002 requirements, making them suitable for low Earth orbit (LEO) applications.

Laser additive manufacturing is creating new possibilities for building and maintaining technology in space. With 3D printing already on the ISS and work being done for lunar and Mars missions, the aerospace industry is making it more possible to create tools and components on-site, cutting down on costly supply missions. As the technology develops, it will help facilitate smarter, lighter, and more resilient missions.

Sources

[1]https://redwirespace.com/newsroom/redwire-to-demonstrate-in-space-additive-manufacturing-for-lunar-surface-on-the-international-space-station/
[2]https://www.nasa.gov/image-article/international-space-stations-3-d-printer-2/
[3]https://www.esa.int/Science_Exploration/Human_and_Robotic_Exploration/ESA_launches_first_metal_3D_printer_to_ISS
[4]https://www.bam.de/Content/EN/Interviews/materials-interview-jens-guenster-powder-based-additive-manufacturing-in-space-2.html
[5]https://www.nasa.gov/mission/in-situ-resource-utilization-isru/
[6]https://technology.nasa.gov/patent/KSC-TOPS-88