Space Forge recently announced an exciting program to harness the special environment of orbit for new innovations. Their goal is to produce cutting edge semiconductor materials in space. In December, the San Francisco-based company operationalized an orbital furnace on the company’s ForgeStar-1 satellite. This was an important step for producing the super-hot plasma, which can grow near-perfect semiconductor crystals in micro-gravity.
This cutting-edge technique produces seed crystals for substrates of gallium and aluminum nitride or silicon carbide. These materials are essential for the development of next generation, high-performance power devices. Space Forge captures the distinct microgravity conditions of space to manufacture materials with superior properties and keep them protected. This method seeks to remove the difficulties that gravity creates for crystal growth and manufacturing on Earth.
It’s clear that Space Forge’s efforts are making big waves across the industry. The in-orbit manufacturing market in particular is expected to skyrocket, hitting a staggering $28.19 billion by 2034. The company would do well in a rapidly growing industry that taps into the advantages of producing materials in space. This innovation is now making inroads in other industries, notably pharmaceuticals and electronics.
Advancements in Crystal Growth
The ForgeStar-1 satellite will be the first test of the in-space orbital furnace. It will showcase its unique capacity to produce and maintain the specialized environment required for superconductor crystal growth. Gravity can mess with that process, particularly when it occurs on Earth, says Joshua Western, co-founder and CEO of Space Forge.
“On Earth, you have trouble that, perhaps, some crystals grow around the interior of the reactor and not in other parts because the process between hot and cold is influenced by gravity,” – Joshua Western.
Compared to that, convection issues are removed by microgravity conditions in orbit, providing a “perpetually homogenous deposition zone.” This homogeneity can lead to the growth of bigger, more uniform crystals. Further, these crystals might have better optoelectronic performance properties than those grown terrestrial. Just last week, a large meta-analysis study published in Nature yielded remarkable findings. As a result, 86% of the semiconducting crystals produced in microgravity aboard spacecraft showed improved properties.
Western further pointed out that in space, the spatial setting and atmospheric conditions are drastically different than those on Earth. For example, nitrogen concentrations can be orders of magnitude lower, reducing the risk of NE contamination during crystal growth.
“For example, if you’re worried about nitrogen interfering with your growth process, on Earth [in a vacuum chamber] nitrogen might be present at concentration of around 10 to the -11,” – Western.
“In space, above 500 kilometers altitude, it’s naturally present at 10 to the -22.” – Western.
These factors indicate that Space Forge’s approach could greatly accelerate and even revolutionize semiconductor manufacturing through higher yield rates and material purity.
Implications for High-Performance Electronics
Space Forge manufactures advanced, high-performance materials in the space environment. Their vision is to develop ultra-efficient, next-generation electronics and ultrafast optical networks. The possible applications are wide-ranging—from powering our future 5G networks to building the next generation supercomputers.
Steve Putna, a researcher in semiconductor technology, highlighted the significance of space-grown crystals:
“Space-grown crystals have demonstrated significantly higher electron mobility.”
In an environment of larger processors, this increase in mobility might be sufficient to bring large productivity gains in processing capacity. Putna further elaborated on the financial implications:
“If a space-grown substrate increases the yield of a $10,000 high-end AI processor from 50 percent to 90 percent or allows a quantum computer to function closer to room temperature rather than near absolute zero, the launch cost becomes a negligible fraction of the total value created.” – E. Steve Putna.
Future Missions and Market Potential
Space Forge appears to be reaching readiness to return its first space-grown crystals to Earth. They plan to fly a follow-on mission next year. The company is optimistic about establishing itself as a leader in space-based manufacturing amidst rising competition from various companies venturing into this field.
The marginal launch costs of sending additional payloads to low-Earth orbit are significant to mention. SpaceX’s Falcon 9 has introduced a new price point making it $1,500 per kilo affordable. This pricing allows companies like Space Forge to return materials from the International Space Station (ISS). As demand for these ancillary services increases, the supply will likely get tight.
Matt Francis, an expert in semiconductor markets, commented on the evolving landscape of production costs:
“While I remember paying $20k a wafer in the early days, we are down in the hundreds of dollars range in volume markets like power.” – Matt Francis.
Space Forge is committed to leading innovation in this new evolving market. In doing so, it intends to create powerful technological and economic advancements.