​Vast, a pioneering company in space habitation technologies, has unveiled the integration of large 3D printed cold plates into its Haven-1 space station’s thermal control system. These additively manufactured components are designed to efficiently transfer heat away from avionics components into the station’s thermal control fluid, ensuring that both equipment and crew operate within safe temperature limits.
The production of these cold plates for the Vast space station utilizes metal laser powder bed fusion (M-L-PBF) technology. This capability stems from Vast’s strategic acquisition of Launcher in February 2023, a move to accelerate the development of long-term human habitation in space.
Following the acquisition, Max Haot, founder of Launcher, assumed the role of President at Vast, overseeing programs such as Orbiter, E-2, and space station development. Additionally, Tim Berry joined as Vice President of Manufacturing, leading the Manufacturing, Supply Chain, and Quality organizations.
Vast can now leverage some of the most advanced additive manufacturing technologies in the aerospace industry to support its ambitious space habitation goals. The 3D printed cold plates destined for the Haven-1 space station are produced using metal PBF systems—specifically the AMCM M 4K platform (as seen in the photos above and below). The company also houses multiple Velo3D Sapphire systems (seen in the image at the top) at its facility.
Launcher, now part of Vast, began using the Velo3D Sapphire system in 2021 to print high-performance rocket engine parts. The first Sapphire printer focused on Inconel, a nickel-based superalloy known for its excellent heat and corrosion resistance—crucial traits for rocket engine applications. Recognizing the benefits, Launcher added a second Sapphire system capable of printing titanium. Titanium offers an outstanding strength-to-weight ratio and is widely used in aerospace structures.
The Velo3D system was the first to enable the production of parts with complex internal geometries without the need for traditional support structures. This flexibility is vital for components like cold plates and engine parts, where internal channels and intricate designs enhance thermal performance and efficiency.
In addition to Velo3D systems, Vast utilizes the AMCM M 4K printer from AMCM (an EOS Group company). This system, installed at Launcher’s Hawthorne, California facility in 2021, can print some of the industry’s largest and most complex single-piece metal parts. It has been fundamental in manufacturing the E-2 rocket engine, producing the world’s largest single-part 3D printed copper alloy combustor.
The M 4K’s large build volume and powerful laser system allow it to fabricate the entire 10-ton-force E-2 rocket engine using copper alloys, which provide excellent thermal conductivity. This capability drastically reduces the number of parts and joins in engine construction, enhancing performance and reducing potential failure points.
Metal additive manufacturing technologies thus remain key enablers of Vast’s mission to create sustainable human habitats in space.
