Over a year ago, the International Space Station (ISS) advanced beyond plastic 3D printing by installing its first metal printer, marking a significant step for in-space manufacturing. Now in a crucial phase of testing, this technology is being refined by NASA astronaut Jeanette Epps of Expedition 72, who is producing stainless steel samples in microgravity. What began as an ambitious installation is steadily becoming a cornerstone of space exploration.
A Milestone in Motion
A collaboration between the European Space Agency (ESA) and Airbus, the metal 3D printer launched aboard NASA’s NG-20 mission and arrived at the ISS’s Columbus module in January 2024. By June 2024, it reached a major milestone: printing an S-shaped stainless steel curve, followed by a disk with cylindrical posts. Astronauts Sunita Williams and Epps retrieved the initial samples in August 2024, which returned to Earth aboard a SpaceX Dragon capsule on December 17. Now at ESA’s technical center in the Netherlands, researchers are analyzing these pieces to compare their structural integrity with parts made on Earth.
Epps’ ongoing efforts, begun in early March 2025, extend this work. She operates the printer to create additional test components, each destined for Earth-side evaluation. The potential is immense: successful implementation could empower astronauts to fabricate durable tools and parts on demand, reducing reliance on Earth-based resupply.
From Plastic to Metal—and Beyond
NASA and Redwire introduced 3D printing to the ISS in 2014 with a plastic printer that produced a ratchet wrench under astronaut Butch Wilmore’s supervision. By 2016, the Additive Manufacturing Facility (AMF) enhanced this capability with greater material strength. The Refabricator, installed in 2019 by Anne McClain, advanced the concept further, recycling plastic waste into fresh filament—a stride toward orbital sustainability.
The transition to metal marks a significant step forward. To ensure safety within the ISS’s confined environment, the printer employs a sealed design, substituting nitrogen for oxygen to manage its high-powered laser. Though modest in scale, its early outputs herald a shift toward crafting durable components—vital for deep-space missions.
Testing the Limits
Recent advancements reach beyond metal printing. The Redwire Regolith Print project has tested simulated lunar soil as feedstock, suggesting a future where habitats could rise from extraterrestrial materials. Bioprinting trials have explored generating human tissues—essential for long-term space health and offering promising applications in terrestrial medicine. Alongside Epps’ work, these projects position the ISS as a hub for developing self-sustaining space technologies.
The samples returned in December 2024 provide initial insights: microgravity seems to have little effect on metal printing, though thorough testing continues. Epps’ latest prints will deepen this knowledge, laying the groundwork for a catalog of dependable designs.
A Broader Horizon
The impact extends beyond orbit. Techniques honed in space are advancing terrestrial industries—automotive, aeronautical, maritime—where efficiency reigns supreme. Recycling breakthroughs from the Refabricator could bolster waste reduction on Earth, while regolith printing might one day enable resource-scarce regions to rebuild with local materials.
As Epps operates the printer 250 miles above Earth, the ISS serves as both a scientific platform and an innovation hub. With each layer of molten steel, she is not merely printing a part; she is forging what lies ahead.
Reference Link:
https://www.nasa.gov/missions/station/iss-research/3d-printing-saving-weight-and-space-at-launch/
