Burloak and MDA scale metal AM for satellite constellations
The rise of large LEO constellations such as Telesat Lightspeed, Starlink, and Kuiper has disrupted traditional one-off satellite manufacturing, creating a need for scalable, repeatable production
Metal additive manufacturing has moved from niche use to a core production method in the space sector, driven by demand for high-performance, low-mass components and accelerated satellite manufacturing cycles. Burloak Technologies, Canada’s largest metal AM contract manufacturer, has invested heavily in process validation to meet spaceflight’s stringent requirements. Its vertically integrated capabilities—proprietary heat treatments, Hot Isostatic Pressing (HIP), and advanced surface finishing—enable production of flight-critical hardware that matches or exceeds conventionally machined components.
The rise of large LEO constellations such as Telesat Lightspeed, Starlink, and Kuiper has disrupted traditional one-off satellite manufacturing, creating a need for scalable, repeatable production. AM’s ability to eliminate tooling, consolidate assemblies, and produce complex RF components—such as waveguides and antennas with optimized internal geometries—has reduced lead times from months to weeks while improving performance metrics like signal integrity and mass efficiency.
Burloak’s partnership with MDA Space exemplifies this shift. The company is supplying over 50,000 Ka-band metal AM antennas for MDA’s AURORA software-defined satellites for the Lightspeed constellation. High-performance aluminum and titanium components are enabling MDA to reduce part counts, optimize mass, and enhance RF performance.
MDA is scaling its production to deliver two AURORA satellites per day, supported by Burloak’s ability to ramp AM and post-processing throughput in lockstep. This capability positions AM as a competitive differentiator in the rapidly expanding satellite economy.
Beyond near-term production, the next frontier is in-space manufacturing—printing large structures in orbit for space stations, lunar habitats, and deep-space missions. This could bypass launch constraints and enable on-site construction and repair, increasing mission flexibility and reducing cost.
Metal AM has now matured into an essential aerospace manufacturing technology, with validated processes, qualified materials, and proven flight heritage. Companies integrating AM at scale into their supply chains will gain speed, flexibility, and performance advantages in a market where time-to-orbit is increasingly critical. For Burloak and MDA, the technology is not a side capability—it’s a foundation for how next-generation space hardware is built.
