The fifth metal sample 3D-printed on the International Space Station (ISS) has made its way to Earth. Made by ESA’s Metal 3D Printer onboard the station’s Columbus module, it was retrieved in July by ESA astronaut Sophie Adenot, and contains the first thrusters created in space.
Only a few months after being launched to the ISS in January 2024, the printer produced its very first complete sample, the first metal part ever created in space. ESA’s material scientists at ESTEC, the agency’s technical heart in the Netherlands, then examined and tested it to investigate how microgravity affected its printing process.
They used their findings to improve the printing procedure for the two bigger parts of the fifth sample. The two smaller parts have been designed by the German Aerospace Center (DLR) and take the form of tiny thrusters – satellite parts used for propulsion.
Florian Merz, research associate and test engineer at DLR, explains the next steps: “We have designed two versions of the thruster: one manufactured as closely as possible to the desired shape, and one with thicker walls that allow for post-processing to refine the thruster’s inner diameter.
“At our vacuum test bench in Lampoldshausen, Germany, we will assess the functionality and performance of the thrusters in hot-fire tests under representative operating conditions, demonstrating that space-manufactured components can achieve the precision required for propulsion and withstand relevant temperatures and pressures.”
Sonja Steinbach, DLR’s project manager, adds: “By comparing the space-manufactured thrusters with equivalent components produced on Earth, we can investigate how microgravity influences the manufacturing process and how these effects translate into the performance of the finished components. The results will help us further optimise metal 3D printing for future in-space manufacturing.”
“Even though we have already received four samples from the ISS at ESTEC, the thrill of opening these very special packages remains the same,” comments Rob Postema, ESA’s technical officer of the project.