The European Space Agency (ESA) has shown off the first 3D metal part printed on the International Space Station (ISS).

3D printing aboard the ISS is nothing new - a device capable of producing plastic parts in microgravity was launched to the space station ten years ago, but plastic only goes so far. However, printing parts from metal has many more applications and extends the range of spares and tools that could be produced while in orbit.

The printer and the raw materials needed for the test were launched to the ISS earlier this year. ESA astronaut Andreas Mogensen installed the hardware in the European Drawer Rack Mark II of ESA's Columbus module.

The first metal shape was produced in August, and three more are planned as part of the experiment. All four will eventually be returned to Earth for analysis - two to ESA's technical center, ESTEC, in the Netherlands, one to the agency's astronaut training center in Cologne, and the last sample to the Technical University of Denmark.

During a panel discussion following the UK premiere of Fortitude, a film about the emerging commercial space industry, Advenit Makaya, Advanced Manufacturing Engineer at ESA, remarked on the potential for recycling space debris in the process rather than having to rely on raw materials launched to the ISS.

Rob Postema, ESA Project Manager for Metal 3D, told The Register that the agency was indeed looking at "circular" solutions in its drive for greater sustainability. However, don't hold your breath for putting bits of space garbage into one end and getting shiny metal parts out of the other:

"A timeline is difficult to indicate, some early results are achieved with ground activities, ready to evaluate solutions in space."

The printer is overseen from the ground and operated for around four hours per day. The ground team has to check each layer via images and a scan of the surface area; printing a sample can take 10-25 days. However, Postema said: "Through automated control of the printing process as well as continuous operations, this can be substantially reduced."

Knick-knacks from orbits are all well and good, but could something more substantial be produced? Yes, although not with this demonstrator, which can print to the outer dimensions of a soft drink can. Postema noted that while the demonstrator could manage smaller parts, either as a single unit or as part of larger structures, "there are definitely opportunities to create 3D shapes and parts with this technology larger than what we have done with this Technology Demonstrator."

Daniel Neuenschwander, Director of Human and Robotic Exploration at ESA said: "With the printing of the first metal 3D shape in space, ESA Exploration teams have achieved a significant milestone in establishing in-orbit manufacturing capabilities.

"This accomplishment, made possible by an international and multidisciplinary team, paves the way for long-distance and long-duration missions where creating spare parts, construction components, and tools on demand will be essential." ®

https://www.theregister.com//2024/09/06/esa_metal_3d_printing/