Space Forge, a UK-based startup founded in 2018, is positioned to do just that. They are setting themselves up to transform the production of advanced materials. The company’s vision is to profit from the favorable environment that only exists in space. They will manufacture semiconductors and pharmaceuticals with an efficiency and quality that is currently unfathomable. Led by CEO Joshua Western, Space Forge has created a satellite, ForgeStar-1. It has just begun testing an orbital furnace for growing semiconductor crystals.
The ultimate goal for Space Forge is to make the materials that can dramatically improve performance in next-generation electronics. The firm plans to use advanced robotics and agile manufacturing techniques to produce the closest-to-perfect semiconductor crystals possible in orbit. This new solution could increase switching efficiency by 20-40% over typical Earth-grown crystals. This breakthrough comes at the perfect moment, as the new space economy’s in-orbit manufacturing sector is about to explode. It’s expected to grow to $28.19 billion by 2034, indicating an increasing demand for space-based production capabilities.
The Launch of ForgeStar-1
Space Forge’s satellite, ForgeStar-1, was fitted with what the company claims is the most advanced orbital furnace ever built which was fully energised last December. This was a momentous step in the company’s plan to create an eventual galaxy of orbital manufacturing. The super-hot plasma produced by the furnace is a necessary element in growing high-quality semiconductor crystals.
“This technology could enable the production of ultra-efficient next-generation electronics and breakthroughs in pharmaceutical research,” said Western. He pointed out that the extreme conditions of space are perfectly suited to grow specific materials. Combined with lower nitrogen interference, these conditions maximize the growth process.
“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,” – Joshua Western
Western also noted that in space, nitrogen is present at very low, nearly trace concentrations. Specifically, at altitudes above 500 kilometers, it’s only 10 to the -22. This dramatic contrast creates a much less competitive environment for semiconductor production.
Future Testing and Challenges Ahead
Looking to the future, Space Forge is planning more tests this year focused on developing its return technology. During any of these aforementioned tests, we will be flying an experimental advanced heat shield. It will be brought into service during the de-orbit maneuver for ForgeStar-1. Western hopes that the satellite will eventually die as it returns safely to earth. Still, he remains hopeful about recovering the first batch of space-grown crystals via a follow-up mission.
“There will be a level of degradation over time and over generations of growth,” – Joshua Western
Western explained that degradation over time was a known factor. They think several growth runs will maintain quality at least until it gets down to today’s levels. This detailed long-term vision is representative of Space Forge’s dedication to mastering its manufacturing processes.
Potential Impact on Electronics and Pharmaceuticals
The potential impacts of Space Forge’s technology go well beyond semiconductors. Analysts believe that advancements in space-grown materials could facilitate significant improvements in various sectors, including 5G technology and quantum computing. Western stressed that energy savings would be significant, with the potential for up to a 50% energy savings integrated into large infrastructure installations.
“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
Many scientists are hesitant to embark on the idea of mass-producing bulk materials in microgravity. They understand that small, targeted applications might be worth the investment in this new, technology-focused approach.
“I don’t think that microgravity is going to be ideal for the manufacture of bulk materials,” – Anne Wilson
Wilson added that “niche materials for specific applications might be worth the investment.” Overall, this perspective represents a cautiously optimistic take on the future potential for orbital manufacturing.
Space Forge is leading the way when it comes to the innovative disruption. It intends to stay at the forefront of the new, burgeoning blend of space exploration and advanced manufacturing. The company’s unique approach and commitment to innovation could potentially lead to breakthroughs that reshape industries reliant on high-performance materials.