Founded in 2018, Space Forge is a European space-tech pioneer. Now they’re on the verge of transforming the electronics industry with their pioneering manufacturing processes in space. The firm has created a one-of-a-kind flying furnace. It develops the world’s highest performance substrates, namely semi- and fully polar gallium and aluminum nitride, and silicon carbide seed crystals. Space Forge is leveraging its new breakthroughs to manufacture near-perfect semiconductor crystals on orbit with these ideal properties. This creative strategy might dramatically improve the performance of cutting-edge electronic gadgets.
In December, Space Forge successfully activated its orbital furnace aboard the ForgeStar-1 satellite, producing a continuous stream of super-hot plasma. This technology demonstration satellite has been designed to prove the ability to manufacture an extremely controlled environment in space. More than a techno-artistic statement, it will continuously produce superconductor crystals. Further, the ForgeStar-1 will deploy a novel heat shield during its de-orbit maneuver later this year. This exciting development, if successful, will further cement its future as a critical part of operational overall strategy.
Space Forge’s goal is to leverage the unique, controlled, and high–opportunity microgravity environment found in space. They want to provide them with the means produce repeatable and reproducible conditions for crystal growth. This innovative approach could lead to significant breakthroughs in next-generation electronics, ultrafast optical networks, and pharmaceutical research by providing higher quality materials than those available on Earth.
Harnessing Microgravity for Crystal Growth
Microgravity environment in space provides unique benefits for crystal growth processes. As Joshua Western, co-founder and CEO of Space Forge, explains, convection from microgravity goes a long way in making sure it doesn’t happen when crystals are formed.
“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
The microgravity conditions in orbit create the idea deposition environment with consistent flatness of surface for optimized crystal growth. This homogeneity provides the system with a “faster crystal growing head start” in the nucleation process.
“In space, above 500 kilometers altitude, it’s naturally present at 10 to the -22,” – Joshua Western
This reduction in nitrogen interference is just one example of how space-grown crystals can achieve higher quality compared to their Earth-grown counterparts. According to the analysts, these breakthroughs would increase switching efficiency by up to 20-40 percent for several flagship high-performance applications.
Economic Potential of Space-Grown Materials
The potential economic impact of Space Forge’s work is massive. Some market analysts estimate that the future in-orbit manufacturing market may be worth an astronomical $28.19 billion by 2034. If we can grow the highest-quality semiconductor materials in space, manufacturers here on Earth stand to benefit enormously.
Starting with only one kilogram of the semiconductor grown in space, producers will be able to create tonnes of the material on Earth. Retrieving that material remains a challenge. As for the amount returned, it will be very limited—no more than a few kilograms at best.
“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
The possible yield increases would help make releasing materials into space an economically sound strategy.
Industry Perspectives on Space Manufacturing
Even with all excitement over the promise of building with materials grown in space, specialists are still wary about applying them more widely. Anne Wilson, analyst in the space technology sector, noted that microgravity isn’t always ideal for creating bulk materials. Still, she pointed to the possibility of sometimes high returns in limited use cases.
“However, niche materials for specific applications might be worth the investment,” – Anne Wilson
Industry veterans like Matt Francis are in full agreement with this sentiment. These reports provide important information regarding trends in semiconductor 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
Francis was doubtful of the economic case for manufacturing in space. He thinks that as manufacturing costs on Earth keep dropping, it’ll be hard to compete with something produced in space.
“When they were a prized commodity, maybe sending to space made sense. While the cost of space is decreasing, it’s not decreasing faster than the cost of producing wafers,” – Matt Francis