One of four groundbreaking 3D-printed metal objects has traveled from the International Space Station to DTU. The objects were made on the International Space Station under weightless conditions using a 3D metal printer – and were designed by DTU researchers.
“No one has previously made metal parts using a 3D printer in space. We have shown that it is possible, and that Denmark and the EU are at the forefront of developing new space technology. It fits very well into the plans to make the space station a space-based microgravity laboratory for industry,” explains John Leif Jørgensen, professor at DTU Space and scientific leader of the Danish part of the 3D printing experiment.
The project is a collaboration with Airbus, ESA, and the Danish astronaut and adjunct DTU professor Andreas Mogensen.
Together with experts from, among others, the Danish Technological Institute, John Leif Jørgensen and his colleagues will now begin to examine the 3D product closely and compare it with a similar object made on Earth. In total, just four metal objects have been produced with the printer on the space station. This is the first time this kind of manufacturing has been done in space. One of the prints belongs to DTU.
Denmark is thus among the first in the world to investigate whether it is possible to produce metal objects in space, and whether it can be done in the desired quality.
A good example of future European space technology
DTU’s provost, Christine Nellemann, participated in the presentation of the object at the Danish Industry Federation (DI) today. She sees the project as an example of how Denmark and Danish researchers are at the forefront of developing new space technology:
“This collaboration between DTU, ESA, and Airbus clearly shows what we can achieve in Denmark and Europe when authorities, industry, and universities pull in the same direction. DTU has been involved in the development of new space technology for more than 60 years, and we have shown that we can deliver reliable components for some of the largest space missions. This has contributed to the fact that Denmark today have a space industry of around 240 companies, which generates up to six billion kroner annually,” she says.
The provost is supplemented by the deputy director for education, research, and diversity at DI, Mikkel Haarder:
“The numbers speak for themselves. Investments in space research are a good idea for both society and our companies. It increases our understanding of the universe and creates better solutions, growth, and jobs through the technology developed for space travel. And it is important that space research also contributes to increasing interest in science and technology. Hopefully, it will mean that more young people will open their eyes to the technology and science that are needed to solve humanity's challenges”.
The metal object made in space will be compared with a copy from Earth
The 3D-printed metal object do not have any function in itself, but DTU’s design is made to uncover and explore the limits and possibilities of what can be done when 3D printing with metal in weightless conditions.
The purpose of the experiment is thus to understand how the metal printing process in space differs from manufacturing here on Earth. Manufacturing in space may prove to be both faster and cheaper than sending equipment up from Earth, for example during long missions to the Moon or Mars.
“This technology can become an important element in future space travel. If we can produce parts and structures directly in space, it will be one of the major new trends in future space exploration,” explains John Leif Jørgensen.
A collaboration with great potential
The space technology division at Airbus has delivered the 3D metal printer to ESA. The printer was then sent to the space station in 2024 and installed in the Columbus module by Andreas Mogensen and colleagues. Mogensen's successors on the space station then produced the prints.
“It has gone smoothly to produce the four metal items using the printer on the space station,” says Andreas Mogensen.
The printing took several weeks, partly to make the process as smooth as possible and to free up time for other tasks for the astronauts on the space station.
“Now I look forward to experts and researchers at DTU and their partners examining the metal object in detail,” says Andreas Mogensen.
The project has great potential, notes John Leif Jørgensen.
“The possibilities are great. Among other things, due to the minimal gravitational influence in space, which means that larger constructions can be made both strong and very light. This means that the material requirement is significantly less than when manufacturing on Earth, which opens up new possibilities for creating efficient and resource-saving structures in space,” he says.
“For example, one could imagine to print the structure for a large solar cell element on a base on the moon. Or even produce complete, ultra-light and resource-saving solar farms. Then you could produce your own energy source directly in space”.
