Space & Satellites
Innovative 3D Printing Solutions for Space Spare Parts Production
Space exploration has always been about pushing boundaries and venturing into the unknown. Today, one of the most significant challenges is ensuring the sustainability and self-sufficiency of missions beyond Earth. Unlike terrestrial aircraft, spacecraft cannot simply land for repairs or maintenance. This has led to the development of innovative technologies like 3D printing, or additive manufacturing, to produce spare parts and tools in space. This capability not only reduces reliance on Earth-based supply chains but also opens the door to a burgeoning space-borne manufacturing industry.
Recent advancements in 3D printing technology have been tested in microgravity environments, with missions like Virgin Galactic’s Galactic 07 and experiments conducted aboard the International Space Station (ISS). These tests aim to refine the technology and understand its potential for long-term space missions, lunar bases, and even Martian habitats. By producing spare parts in space, astronauts can address unforeseen issues without waiting for resupply missions from Earth, significantly enhancing mission flexibility and safety.
3D printing in space is not just about creating spare parts; it’s about revolutionizing how we approach space exploration. Taylor Waddell, a pathways engineer at NASA and project leader of the SpaceCal initiative, highlights the versatility of 3D printing. From dental crowns to nuts and bolts, the technology can produce a wide range of items using materials like silicones, hard acrylics, biogels, and even metals. This adaptability makes 3D printing an invaluable tool for reducing mission risks and ensuring the success of long-duration missions.
One of the key challenges in space manufacturing is the behavior of materials in microgravity. For instance, liquid propellants in spacecraft tanks can slosh unpredictably, affecting the vehicle’s stability. Purdue University’s experiments aboard the Galactic 07 mission studied this phenomenon to improve spacecraft design. By understanding how liquids behave in zero gravity, engineers can develop safer and more efficient systems for future missions.
Additionally, the European Space Agency (ESA) and Airbus have been testing metal 3D printing on the ISS. Rob Postema, part of the ESA’s Low Earth Orbit Exploration Group, explains that continuous microgravity on the ISS allows for more comprehensive testing compared to suborbital flights. The ability to print metal parts in space could be a game-changer for maintaining the ISS, lunar bases, and future Mars habitats.
“3D printing in space will become commonplace because there are more private space stations being planned, including lunar and Martian habitats. It enables the production of things that people can’t predict before a mission.” – Taylor Waddell, NASA Pathways Engineer
Despite its potential, in-space manufacturing faces several challenges. One of the primary concerns is the accuracy and quality of 3D-printed parts in microgravity. Anthony Moody, a former researcher on the SpaceCal project, emphasizes the importance of testing in controlled environments to improve the printer’s design. For example, adding vibration isolation to the printer can enhance its performance in space.
Another challenge is the noise generated by 3D printers, which limits their operation on the ISS to four hours a day. Rob Postema suggests that artificial intelligence and machine learning could automate the printing process, reducing the need for crew intervention and allowing for remote operations from Earth. This would not only improve efficiency but also free up astronauts to focus on other critical tasks. Looking ahead, the growth of private space stations and extraterrestrial habitats will likely drive the demand for in-space manufacturing. As Taylor Waddell notes, 3D printing is a “useful tool for space exploration,” and its applications will continue to expand as the technology matures. From creating tools on-demand to building structures on the Moon or Mars, the possibilities are endless.
The ability to produce spare parts in space represents a significant leap forward in space exploration. By leveraging 3D printing technology, astronauts can address unforeseen challenges, reduce mission risks, and extend the lifespan of spacecraft and habitats. The experiments conducted aboard the Galactic 07 mission and the ISS have provided valuable insights into the behavior of materials in microgravity, paving the way for more advanced manufacturing techniques.
As we look to the future, in-space manufacturing will play a crucial role in enabling long-duration missions and establishing permanent extraterrestrial bases. With ongoing advancements in automation, materials science, and artificial intelligence, the potential for this technology is limitless. The journey to make space exploration more sustainable and self-sufficient has only just begun.
Question: How does 3D printing work in microgravity? Question: What are the benefits of producing spare parts in space? Question: What challenges does in-space manufacturing face? Sources: Aerospace Testing International, Wikipedia – Space Manufacturing
Testing Ways to Produce Spare Parts in Space
The Role of 3D Printing in Space
Challenges and Future Opportunities
Conclusion
FAQ
Answer: 3D printing in microgravity uses specialized printers that can operate in zero-gravity environments. These printers use materials like liquid plastic or metal to create parts layer by layer, often using light or heat to solidify the material.
Answer: Producing spare parts in space reduces the need for resupply missions from Earth, enhances mission flexibility, and allows astronauts to address unexpected issues quickly. It also supports the sustainability of long-duration missions and extraterrestrial habitats.
Answer: Challenges include ensuring the accuracy and quality of printed parts, managing the noise and vibrations of 3D printers, and automating the manufacturing process to reduce crew workload.
Space & Satellites
Slingshot Aerospace on Fast Company’s 2026 Most Innovative List
Slingshot Aerospace recognized by Fast Company in 2026 for AI-driven space defense tech and key U.S. Space Force contracts.
On March 24, 2026, Slingshot Aerospace announced its inclusion in Fast Company’s annual “World’s Most Innovative Companies of 2026” list. The company was specifically recognized within the Defense Tech category, highlighting its ongoing development of artificial intelligence-powered solutions for the space sector.
According to the official press release, the recognition centers on Slingshot’s pioneering role in Space Operations Intelligence & Autonomy (SOIA). The company provides specialized platforms that assist government, defense, and commercial partners in tracking, interpreting, and responding to activities within an increasingly complex orbital environment.
This is not the first time the publication has highlighted the firm’s technological advancements. In 2024, Slingshot Aerospace was ranked No. 48 on Fast Company’s overall “World’s 50 Most Innovative Companies” list and was featured prominently in the Space category. We at AirPro News note that this latest accolade follows a series of significant defense contracts and security certifications achieved by the company over the past two years.
Slingshot Aerospace has positioned itself as a category creator and leader in SOIA. The company’s core mission involves transforming disparate space data into a unified, common operating picture to strengthen both space-based defense and commercial capabilities.
To achieve this, the company relies on its proprietary infrastructure. According to the provided company data, the Slingshot Global Sensor Network operates a resilient, distributed space object tracking system comprising over 200 daytime and nighttime optical sensors. These sensors are distributed across more than 20 sites globally.
This hardware network feeds directly into the Slingshot Platform, which utilizes advanced space object tracking, artificial intelligence, astrodynamics, and data fusion. The resulting dynamic operational pictures are used for training, planning, and live mission execution by high-profile clients, including Department of Defense (DoD) agencies such as the U.S. Space Force, U.S. Air Force, and DARPA, as well as civil agencies like NOAA and NASA.
The Fast Company award in the Defense Tech category is underpinned by several major operational and financial developments between 2024 and 2026. On January 15, 2026, Slingshot secured a $27 million contract with the U.S. Space Force. The company stated this funding is directed toward modernizing scenario training for space warfare. As part of the Space Force’s Operational Test and Training Infrastructure (OTTI) program, Slingshot is integrating an autonomous, AI-powered agent named “TALOS.” This system realistically imitates satellite behavior and machine-speed adversaries to help Guardians train in a digital environment that mirrors modern orbital threats.
Other notable agreements include a January 2025 selection by the Space Force to provide technology specifically designed for detecting GPS jamming and spoofing threats. Additionally, in December 2024, the company was awarded a $13.3 million contract by the National Oceanic and Atmospheric Administration (NOAA) to develop the user interface for the Traffic Coordination System for Space (TraCSS).
On February 24, 2026, the company achieved Cybersecurity Maturity Model Certification (CMMC) Level 2. This certification validates Slingshot’s capability to protect Controlled Unclassified Information (CUI) for DoD missions, allowing the secure deployment of its AI-powered tracking capabilities within highly sensitive defense environments.
“This achievement represents more than a compliance milestone for Slingshot Aerospace. It reaffirms our deep-rooted culture of excellence and our unwavering commitment to protecting the critical data that underpins U.S. and allied space missions,” said Tim Solms, CEO of Slingshot Aerospace, in the company’s release. The inclusion in the 2026 Fast Company list reflects broader organizational growth and a strategic focus on actionable intelligence in contested environments.
“This award reflects the powerful combination of Slingshot’s innovative culture, our talented and empowered team’s creativity, the visionary leadership of our co-founders, and strong investor support. It underscores our commitment to delivering AI solutions that fuse data into actionable insight, enabling faster decisions and confident action in today’s contested space environment,” Solms stated regarding the Fast Company recognition. We observe that Slingshot Aerospace’s transition from commercial space traffic coordination to advanced, AI-driven counterspace training and threat detection aligns closely with broader geopolitical and aerospace trends. The militarization of space has accelerated, with near-peer adversaries advancing autonomous space capabilities and adopting real-time maneuver tactics.
Industry data indicates that as of early 2024, there were over 8,300 active satellites in orbit, a number that continues to grow rapidly due to commercial mega-constellations. Helping operators avoid collisions and dodge space debris has become a critical sector of the space economy. Slingshot’s focus on autonomous space capabilities directly addresses the DoD’s urgent need to monitor and respond to threats in this vital warfighting domain, bridging the gap between commercial space technology and national security.
What category did Slingshot Aerospace win in Fast Company’s 2026 list? What is the Slingshot Global Sensor Network? What is the TALOS AI agent? Sources: Slingshot Aerospace
Slingshot Aerospace Named to Fast Company’s 2026 Most Innovative Companies List
Pioneering Space Operations Intelligence
Global Sensor Network and AI Integration
Recent Milestones Driving the 2026 Recognition
Major Defense and Civil Contracts
Security and Compliance Achievements
Leadership Perspectives on Innovation
AirPro News analysis
Frequently Asked Questions (FAQ)
Slingshot Aerospace was recognized in the Defense Tech category for 2026.
It is a distributed space object tracking network comprising over 200 daytime and nighttime optical sensors located across more than 20 sites globally.
TALOS is an autonomous AI agent developed by Slingshot Aerospace to imitate satellite behavior and adversaries for U.S. Space Force training. Its integration is funded by a $27 million contract awarded in January 2026.
Photo Credit: Slingshot Aerospace
Space & Satellites
Pulsar Fusion Achieves First Plasma in Sunbird Fusion Rocket System
Pulsar Fusion successfully demonstrates first plasma in its Sunbird nuclear fusion rocket exhaust, advancing deep-space propulsion technology.
UK-based space propulsion Startups Pulsar Fusion has successfully achieved “first plasma” in its Sunbird nuclear fusion rocket exhaust system, marking a critical milestone in the development of next-generation deep-space travel. In a company press release, Pulsar Fusion announced that the successful test represents the first physical demonstration of plasma confinement within a nuclear fusion exhaust architecture designed specifically for spaceflight.
The breakthrough was showcased live during a dedicated technical session at Amazon’s MARS Conference in Ojai, California. According to the official release, the demonstration offers a glimpse into a future where interplanetary transit times could be drastically reduced, potentially revolutionizing how humanity explores the solar system.
The historic test was conducted by Pulsar Fusion scientists at the company’s headquarters in Bletchley, United Kingdom, and live-streamed to an audience of astronauts, Nobel laureates, and robotics experts at the MARS Conference. In the press release, the company detailed that the experiment utilized a combination of powerful electric and magnetic fields to guide and accelerate charged particles through the exhaust channel.
For this initial series of tests, the engineering team selected krypton gas as the propellant. The official release notes that krypton was chosen due to its relatively high ionization efficiency and inert characteristics at the mass flow rates required for early-stage testing. By successfully generating and confining the superheated plasma, Pulsar Fusion has cleared a major initial hurdle in harnessing fusion power for propulsion.
Current spacecraft rely heavily on chemical propulsion, which provides high thrust but low exhaust velocities, or Electric-Aviation propulsion, which offers high efficiency but very low thrust. Fusion propulsion aims to deliver both. According to the company’s press release, the Sunbird Migratory Transfer Vehicle is designed to provide continuous high-thrust propulsion for faster and more efficient travel.
Industry estimates reported by Gizmodo suggest that Pulsar Fusion’s Dual Direct Fusion Drive (DDFD) engine could achieve a remarkably high specific impulse of 10,000 to 15,000 seconds. Furthermore, according to World Nuclear News, the system is designed to generate 2 megawatts of power, providing both continuous thrust and electricity to run spacecraft systems upon arrival at a destination. With this technology, a fusion rocket could theoretically reach speeds over 500,000 miles per hour, according to reporting by Payload Space. This would allow spacecraft to cut the transit time to Mars by half and potentially reach Pluto in just four years, as outlined by World Nuclear News.
Following the successful first plasma test, Pulsar Fusion plans to gather detailed performance data, including thrust and exhaust velocity measurements, to plan the first official Sunbird mission. The press release outlines upcoming hardware upgrades, including the transition to rare-earth, high-temperature superconducting magnets. These magnets will enable stronger magnetic fields, allowing the team to explore higher plasma density and pressure conditions. To maximize the operational lifespan of the Sunbird engine, Pulsar Fusion has also partnered with the UK Atomic Energy Authority. According to the release, this collaborative research program will study the effects of neutron radiation on reactor walls and magnets, a primary cause of wear in fusion systems. Ultimately, the company aims to transition to aneutronic fusion fuel cycles, utilizing Deuterium and Helium-3. Pulsar Fusion is targeting an in-orbit demonstration of the system’s core components by 2027, with hopes for a production-ready vehicle in the early 2030s, according to timelines published by World Nuclear News.
The successful ignition of plasma in a fusion exhaust system represents a monumental engineering feat, but the road to a flight-ready nuclear fusion rocket remains long. Operating an engine at temperatures hotter than the sun’s core requires materials and containment systems that push the boundaries of current material science. However, the economic incentives are substantial.
“With the space economy projected to exceed $1.8 trillion by 2035, faster in-space transport isn’t just a scientific goal; it’s an economic one.”
, Pulsar Fusion statement, as cited by The Independent
This statement highlights the commercial viability of the project. If fusion propulsion can be mastered, we believe it will not only reduce the health risks for astronauts by shortening their exposure to deep-space radiation and microgravity but also enable rapid cargo delivery and asteroid mining missions that are currently unfeasible with chemical rockets.
In nuclear fusion, “first plasma” refers to the initial successful generation and confinement of superheated, ionized gas (plasma) within a reactor or exhaust system. It is a critical proof-of-concept milestone for fusion technology.
According to industry reports, the Sunbird nuclear fusion rocket could theoretically reach speeds exceeding 500,000 miles per hour, drastically reducing travel times to destinations like Mars and Pluto.
Pulsar Fusion plans to conduct an in-orbit demonstration of the system’s core components in 2027, with the goal of having a production-ready Sunbird vehicle operational in the early 2030s.
Demonstrating the Sunbird Exhaust System
Live from Bletchley to California
Redefining Deep-Space Propulsion
Speed and Efficiency Upgrades
Next Steps and Challenges
Upgrades and In-Orbit Testing
AirPro News analysis
Frequently Asked Questions
What is “first plasma”?
How fast could the Sunbird rocket travel?
When will the Sunbird rocket launch?
Sources
Photo Credit: Pulsar Fusion
Space & Satellites
Firefly Aerospace Supports U.S. Space Force VICTUS DIEM Rapid Launch Exercises
Firefly Aerospace aided Lockheed Martin in U.S. Space Force VICTUS DIEM exercises, demonstrating rapid payload processing and 36-hour launch simulations.
This article is based on an official press release from Firefly Aerospace.
Manufacturers Firefly Aerospace has successfully supported Lockheed Martin in a pair of responsive space exercises for the U.S. Space Force, advancing the military’s rapid-launch capabilities. The operations were conducted as part of the VICTUS DIEM mission, an initiative designed to test and refine emergency launch protocols for tactically responsive space missions.
According to an official press release from Firefly Aerospace, the exercises demonstrated the ability to rapidly process payloads and execute launch procedures under highly compressed timelines. These demonstrations are critical for the Space Force as it seeks to build a repeatable process for deploying assets into orbit during real-world threat scenarios.
We note that the VICTUS DIEM program relies heavily on commercial partnerships to generate new opportunities for rapid launch capabilities within government frameworks. By collaborating with private sector companies, the U.S. military aims to codify a streamlined approach to tactically responsive space operations.
The recent VICTUS DIEM exercises were divided into two primary demonstrations, each testing different phases of a rapid-response launch. In the first exercise, Firefly Aerospace and Lockheed Martin completed a rapid payload processing demonstration. As detailed in the company’s press release, this phase included spacecraft arrival operations, system checkouts, mating, and encapsulation,all of which were successfully completed in under 12 hours.
The second exercise focused on the Launch sequence itself, simulating a 36-hour rapid launch scenario. This drill was designed to practice the emergency protocols required to execute a mission under a simulated threat.
Working alongside Space System Command’s (SSC) System Delta 89 Tactically Responsive Space Program,commonly known as Space Safari,and SSC’s Space Launch Delta 30, the team executed a comprehensive array of pre-launch requirements.
“The team completed the initial mission design, flight trajectory planning, launch collision avoidance analysis, range safety protocols and authorizations, and all final launch operations within 36 hours of receiving a simulated notice to launch,” Firefly Aerospace stated in its release.
The VICTUS DIEM mission was specifically created to expand the U.S. Space Force’s ability to respond to orbital threats with unprecedented speed. By leveraging commercial Partnerships, the government process for authorizing and executing space launches is being continuously refined. The results of these recent exercises provide a continued focus on establishing a repeatable, codified process for rapid launches. This aligns with the broader goals of the VICTUS program, which seeks to ensure the United States can maintain and protect its space-based infrastructure on short notice.
The successful completion of the VICTUS DIEM exercises underscores a growing reliance on commercial space companies to fulfill critical national security objectives. Firefly Aerospace notes in its release that it is the only commercial company to have launched a satellite to orbit with approximately 24-hour notice. As the U.S. Space Force continues to prioritize tactically responsive space capabilities, companies with proven rapid-turnaround hardware and streamlined operational protocols will likely secure a competitive advantage in future defense Contracts. The ability to condense months of mission planning and payload integration into a 36-hour window represents a significant shift in orbital logistics.
VICTUS DIEM is a U.S. Space Force exercise designed to test and refine rapid launch capabilities and emergency protocols for tactically responsive space missions.
According to the Firefly Aerospace press release, the rapid payload processing demonstration,including spacecraft arrival, checkouts, mating, and encapsulation,was completed in under 12 hours.
The team completed all necessary mission design, trajectory planning, safety protocols, and final launch operations within 36 hours of receiving a simulated notice to launch.
Rapid Payload Processing and Launch Simulations
Collaborative Mission Planning
The Strategic Importance of VICTUS DIEM
AirPro News analysis
Frequently Asked Questions
What is the VICTUS DIEM mission?
How fast was the payload processing completed?
What was the timeframe for the rapid launch simulation?
Sources
Photo Credit: Firefly Aerospace
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