The logistical burden of resupplying future Moon bases with tools or load bearing parts could be alleviated if astronauts could manufacture such items with a metal 3D printer.

To that end, the first metal 3D printer launched on January 30, 2024 onboard NASAs mission NG-20, which is heading to the International Space Station on a resupply mission.

In the coming days the printer will be set-up in the Columbus module the science lab onboard the ISS - by astronaut Andreas Mogensen and operated to 3D print the first metallic part in space.

The printer was developed by Airbus, AddUp, Cranfield University and Highftech Engineering under a European Space Agency (ESA) programme.

In a statement, Gwenalle Aridon, Airbus Space Assembly lead engineer, said: Astronauts will be able to directly manufacture tools such as wrenches or mounting interfaces that could connect several parts together. The flexibility and rapid availability of 3D printing will greatly improve astronauts autonomy.

Sbastien Girault, metal 3D printer system engineer at Airbus, said the printer is the size of a washing machine and can print parts that are 9cm high and 5cm wide.

As well as overcoming the challenge of size, the printer will sit in a sealed metal box to protect against the aggressive printing environment caused by the laser and the heat it generates.

Gravity management is also key, which is why we chose wire-based printing technology, said Girault.

Furthermore, fumes that are emitted will be addressed by filters and captured inside the machine so that they do not contaminate the air inside the ISS.

Two printers will be used for this experiment: the flight model inside the ISS; and the engineering model on Earth. The astronauts will print four samples in space, which will be sent back to Earth for analysis. The same specimens will be manufactured using the engineering model printer.

In order to evaluate the effects of microgravity, ESA and Danish Technical University will perform mechanical strength and bending tests and microstructural analysis on the parts made in space and compare them to the other specimens, said Girault.

According to Airbus, there are several plastic 3D printers on board the ISS and Astronauts have used them to replace or repair plastic parts that would have taken months to arrive if built and transported from Earth.

This logistical constraint will intensify on future Moon and Mars stations; the raw material will still need to be launched, but printing the part is still more efficient than transporting it to its destination.

Increasing the level of maturity and automation of additive manufacturing in space could be a game changer for supporting life beyond Earth, said Aridon. Thinking beyond the ISS, the applications could be amazing. Imagine a metal printer using transformed regolith or recycled materials to build a lunar base.

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First metal 3D printer heading to International Space Station - The Engineer