ESA’s ISS metal printer produces further thrusters made in space
Fifth sample from the Columbus module printer returned to Earth with two DLR-designed thruster versions
The European Space Agency (ESA) has reported that the fifth metal sample printed on the International Space Station (ISS) returned to Earth carrying the first thrusters created in space. ESA astronaut Sophie Adenot retrieved the sample in July from ESA’s metal 3D printer, which operates in the station’s Columbus module.
The sample consisted of four parts: two larger ones and two smaller thrusters, the latter being satellite propulsion components designed by the German Aerospace Center (DLR).
Process changes after the first sample
ESA launched the printer to the ISS in January 2024. A few months later, it produced its first complete sample, the first metal part created in space.
Material scientists at ESA’s technical center ESTEC in the Netherlands examined and tested that part to study how microgravity affected the printing process, then used the results to improve the procedure for the two larger parts of the fifth sample.
Two thruster versions
“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,” said Florian Merz, Research Associate and Test Engineer at DLR.
“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, Project Manager at DLR, said the tests would include a comparison with Earth-built parts.
“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.”
Rob Postema, Technical Officer of the project at ESA, commented on receiving the samples. “Even though we have already received four samples from the ISS at ESTEC, the thrill of opening these very special packages remains the same.”
