ISS Returned Fifth Metal 3D-Printed Sample in July 2026
The sample included space-manufactured satellite thrusters designed to undergo performance testing on Earth.
Updated on Oct. 1, 2026 in Space
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In July 2026, the International Space Station returned its fifth metal 3D-printed sample to Earth. This batch featured the first satellite thrusters successfully created in the microgravity environment of the station's Columbus module.
Why it matters
The successful manufacturing of complex components like thrusters demonstrates that orbital production can potentially meet industrial precision requirements for spacecraft hardware. This milestone marks a transition from experimental printing to testing functional parts for space-based operations.
The fifth sample includes two satellite thruster variants: one near-net-shape part and one reinforced version with thicker walls designed for post-processing.
The players
European Space Agency
An intergovernmental organization focused on the exploration of space through orbital infrastructure and satellite development.
German Aerospace Center
A national research and space agency that designed the thruster components for the printing demonstration.
Sophie Adenot
An astronaut who retrieved the fifth metal sample from the station in July 2026.
The details
The European Space Agency (ESA) Metal 3D Printer on the Columbus module uses a selective laser melting process, a technique that uses a high-power laser to fuse metallic powder layer by layer. Scientists at ESA refined the printing procedure based on diagnostics from the first metal sample produced in early 2024 to improve structural integrity. The thrusters are intended to confirm that parts produced in microgravity can withstand operational conditions and maintain precise geometry.
Timeline
January 2024: The printer was launched to the International Space Station.
July 2026: The fifth metal sample was retrieved from the station.
The Tech Race
The ESA Metal 3D Printer project continues to advance orbital manufacturing by iterating on its printing parameters based on previous test samples. This progression directly supports the goal of creating functional spacecraft components in situ to reduce reliance on Earth-based supply chains.
The thrusters will undergo hot-fire testing in Lampoldshausen, Germany, to validate their performance against established industrial standards. These results will determine the feasibility of on-demand manufacturing for future long-duration deep space missions.
The takeaway
The successful manufacture of thruster components confirms that orbital metal 3D printing is approaching the structural precision required for flight hardware. Researchers will now look to the performance data from the Lampoldshausen hot-fire trials to evaluate the reliability of these space-built parts.
Further reading
Learn more about the latest developments in orbital infrastructure in our Space section.
Source note: This article includes information reported by European Space Agency (ESA).
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