Humanity has always dreamed of conquering space, and every technological advance brings us a little closer to this goal. Among these innovations, 3D printing has emerged in recent years as a major asset for the space industry. But contrary to what you might think, its use in this field is not new.

In 2014, a 3D printer was sent into space for the first time, marking a turning point in the use of this technology in extreme environments. Since then, its applications have continued to evolve. Far beyond small repairs and simple experiments in weightlessness, it is now integrated into rocket design and opens the way to new possibilities, including on-site manufacturing. But why use 3D printing in space? We give you 8 reasons!

To Go to Space

#1: Optimization of Rocket Parts

When it comes to space exploration, every gram counts. The lighter the rocket or satellite, the cheaper and more efficient the launch. By lightening the craft, it is possible to reduce the amount of fuel needed and free up space to carry more useful equipment. To achieve this, 3D printing offers an interesting solution: it can be used to design customized parts, optimized to be both strong and light.

Thanks to DfAM, and topology optimization in particular, it is possible to create complex shapes that are impossible to obtain with traditional methods, all while retaining excellent strength. A concrete example is the cooling ducts used in rocket engines. These small ducts evacuate the intense heat around the combustion chamber. With 3D printing, they can be integrated directly into the parts, which is very difficult, if not impossible, with traditional machining or injection molding as it would be too costly and constraining.

#2: Use New Materials to Improve Performance

In the space sector, materials have to withstand extreme conditions: high temperatures, radiation, pressure variations, thermal shocks, etc. Today, 3D printing makes it possible to use a wide variety of advanced materials, specially adapted to these constraints. These include metal alloys such as titanium, aluminum and Inconel, renowned for their lightness and thermal resistance. Fiber-reinforced composites, meanwhile, offer an excellent compromise between strength, flexibility and reduced weight. But these materials only reveal their full potential when combined with appropriate printing processes.

Technologies such as DED, LPBF, DMLS and extrusion transform them into complex, precise and optimized parts. These methods directly influence the microstructure of printed materials, enabling the creation of customized parts with specific mechanical properties. 3D printing also makes it possible to work with technical ceramics. Zirconia, for example, offers excellent resistance to heat, wear and corrosive environments. This material even becomes conductive at very high temperatures. Other ceramics also offer interesting properties for components subjected to extreme conditions in the space industry.

#3: Simplified Assembly and Reduced Costs

By using 3D printing, manufacturers can produce important parts, such as engine components, more economically. Unlike traditional methods, 3D printing considerably simplifies the manufacturing process. It also facilitates the prototyping and iterations required to design the final product.

Another major advantage is the reduction in the number of components needed to manufacture a spacecraft. Thanks to 3D printing, it is sometimes possible to avoid assembling thousands of parts. For example, SAB Aerospace recently 3D printed a one-piece rocket nozzle, which traditionally requires the assembly of thousands of parts. And Relavity Space has greatly simplified the construction of its Terran rocket, reducing the number of components by 1,000.

To Improve Astronauts’ Daily Lives

#4: Manufacturing Spare Parts in Microgravity

3D printing makes it possible to manufacture objects directly in space. This advance greatly reduces dependence on expeditions from Earth, which are often long and costly. Rather than waiting several weeks, or even months, for a spare part to arrive, crew members can now design and produce what they need on board.

This technical autonomy is invaluable, especially in the event of unforeseen circumstances: if a tool breaks or runs out, they can simply print a new one on the spot. This considerably enhances the safety and efficiency of missions, by limiting interruptions.

Several experiments are underway to explore the potential of 3D printing in space. In 2024, an important milestone was reached when the first metal part was manufactured directly on board the ISS. This kind of test shows that the technology works under space conditions, even if it is still in the trial phase.

#5: Food 3D Printing

Food is a real challenge on space missions, especially when they last several months or even years. Astronauts have to carry large stocks of food, which takes up a lot of space and weight. Food 3D printing makes it possible to prepare meals directly on board, from basic ingredients in paste or powder form.

Furthermore, this makes it possible to create personalized meals for each crew member, taking into account their specific nutritional needs. This technology also reduces waste and optimizes the use of resources.

Tests have already made it possible to create meat using 3D printing, in zero gravity, as on the International Space Station (ISS). At the same time, scientists are continuing to explore whether this technology can really become a reliable solution for feeding astronauts on long missions.

#6: Printing Medical Devices and Bioprinting

On long-duration space missions, it is not always possible to carry all the medical equipment required. Thanks to 3D printing, astronauts can manufacture useful objects on site to treat injuries or certain health problems. For example, they can print splints or even surgical tools adapted to each situation. This means they can react quickly when needed, without having to wait for delivery from Earth.

Bioprinting, the printing of living tissue, is also making headway in space. The Redwire Corporation has successfully 3D printed a meniscus in microgravity, proving that this technology could one day help repair tissue directly in space.

#7: Printing Spacesuits

Making spacesuits on Earth is a major asset for future missions. Once we arrive on the Moon or Mars, it is not enough to be there: we also need to be able to operate safely. In 2023, Axiom Space presented the prototype of a new suit designed for the astronauts of the Artemis program. This model was developed using CAD software, 3D printing and traditional sewing techniques. This type of approach would enable suits to be adapted to local conditions, repaired quickly if necessary, and better meet the specific requirements of each mission.

#8: Building Space Structures and Future Habitats

To live sustainably on the Moon or Mars, it won’t be enough to build simple shelters. With 3D printing, we can now create a wide variety of buildings on site, including housing, solar power plants and other necessary infrastructure. A key advantage of this technology is that it enables the use of local materials, such as regolith.

This makes it possible to build viable structures on site. What’s more, 3D printing can be used to design tailor-made structures to meet the specific challenges of space, such as radiation, extreme temperatures or low gravity.