German Startup Orbital Matter 3D Prints First Rigid Beam in Vacuum of Space
Orbital Matter's satellite successfully 3D printed a half-meter plastic beam in orbit, providing new evidence for building large structures for space data centers.
German startup Orbital Matter announced that its Replicator-2 satellite successfully 3D printed a half-meter long rigid cylindrical beam using a custom plastic material while in orbit. Company executives described this as a first for a free-flying spacecraft and a significant step toward constructing large structures in space.
The satellite was launched on a SpaceX rideshare mission this summer, carrying four 3D printers. Each printer creates a rigid beam by extruding coils of resin cured by ultraviolet light. Jakub Stojek, CEO of Orbital Matter, stated: "Replicator 2 is the first proof that we can simply build the array in space, at whatever size the mission demands."
This technology is critical for future spacecraft, particularly if they serve as orbital data centers. These facilities will need to generate more electrical power and radiate more heat into the vacuum of space while fitting within the tight confines of rocket fairings. If equipment can be constructed in orbit, power and heat-dissipation challenges may become easier to solve.
Current large structures in space typically use folded deployment methods (such as solar arrays or telescope mirrors), which are engineering-intensive. NASA previously funded Redwire to 3D print structural beams in a vacuum chamber in 2023, but these were not tested in orbit. Orbital Matter's test occurred in the actual space environment.
Although one of two printers designed to deploy a flexible solar array failed due to an anomaly, the successfully printed boom completed the solar array deployment task, serving as an important proof of concept. Previous 3D printing efforts in microgravity were limited to the pressurized environment onboard the International Space Station.
The beam's length is limited by the amount of resin carried onboard, but engineers believe 100-meter booms are feasible. For comparison, SpaceX's Starlink V2 satellites use solar arrays that are 20 meters long. Orbital Matter is partnering with the European Space Agency (ESA) and Thales Alenia Space, planning a larger demonstration mission in 2028 aimed at achieving over 100 kW per wing by 2030.