From Earth to Orbit: AddUp and Airbus Propel Metal 3D Printing Into Space

AddUp, a metal additive manufacturing OEM, and Airbus Defence & Space, an aerospace manufacturer, have partnered to provide the European Space Agency (ESA) with the first metal 3D printer to be used in orbit. The two companies look to welcome a new era of space exploration by offering the flexibility and convenience of manufacturing critical space components directly in space.

 

Samples made from AddUp and Airbus’s metal 3D printer before its launch into space. Image used courtesy of ESA

 

Metal 3D Printing Aboard the ISS

Under an ESA contract and co-founded by Airbus, AddUp and Airbus began their “Metal3D” project in 2016. The two companies sought to develop the first metal 3D printer to work safely in microgravity. They focused on optimizing the printer for conditions aboard the International Space Station (ISS). The finished metal 3D printer embarked on its journey on January 30, 2024, with the Cygnus NG-20 resupply mission, where it was then installed aboard the ISS.

The metal 3D printer underwent extensive research and design to meet the needs of the ISS’s unique conditions. Image used courtesy of ESA

 

AddUp and Airbus Collaborate

While polymer-based 3D printers have been used aboard the ISS, metal 3D printers pose a unique challenge, requiring extra safety precautions due to their high-temperature process. The development of AddUp and Airbus’s metal 3D printer has relied on a range of research and engineering expertise. The printer has undergone rigorous design and optimization to meet the needs of the ISS’s unique space environment. 

In a statement by the Head of Engineering at Airbus Systems, Elodie Viau, the experience and knowledge of the AddUp team, together with Airbus's technological expertise, will enable successful, efficient, and high-quality metal 3D printing for space exploration.

 

Components printed aboard the ISS will be compared to similar components printed on Earth. Image used courtesy of ESA

 

Manufacturing in Space

The metal 3D printer will be installed in the ISS, on board the Columbus European Science Module, where it will be tested. Four metal components will be printed on the Columbus module and then analyzed and compared with those printed on Earth. The experiment is focused on testing the viability of in-space metal 3D printing. If successful, the solution from Airbus and AddUp sets the stage for future in-space manufacturing, making it so spare parts and components can be made in space, as opposed to transported from Earth, which can take up to 12 months.