German startup Orbital Matter achieved a milestone by 3D-printing the first rigid beam in the vacuum of space using its Replicator 2 satellite deployed this summer via a SpaceX rideshare mission. The satellite carries four 3D printers capable of extruding ultraviolet-cured resin into cylindrical beams, which the company likens to a cement-and-water mixture. The half-meter beam created marks a critical step toward assembling larger spacecraft structures directly in orbit.

This capability addresses significant challenges faced by future spacecraft, especially orbital data centers requiring large surfaces to generate power and dissipate heat. Current spacecraft must fit into rocket payload fairings, restricting size, but in-space manufacturing allows for scalable construction to suit mission demands. Orbital Matter's CEO Jakub Stojek called Replicator 2 the first confirmation that arrays and structures can be built on orbit at arbitrary sizes.

Orbital Matter collaborated with the European Space Agency and Thales Alenia, a notable satellite manufacturer, on the project. While two printers on Replicator 2 aimed to deploy solar arrays, a malfunction limited operation, yet one beam successfully deployed a flexible solar array, demonstrating proof of concept. This progress builds on earlier efforts, including 3D printing in controlled vacuum chambers and microgravity environments like the ISS, but this is the first rigid structural beam printed on a free-flying satellite.

Founded in 2022, Orbital Matter raised $3 million in seed funding and plans to launch a larger demonstration in 2028 to test printers on bigger satellites capable of deploying solar arrays generating 5 kW, progressing toward 100+ kW wings by 2030. The company is also in talks with satellite manufacturers to integrate its Printer-Assisted Deployment System (PADS) to enable in-space extension of solar panels, antennas, and other components, potentially revolutionizing spacecraft design and assembly.