Space Forge is a UK-based start-up that’s been around since 2018. They are at the forefront of a new materials science and electronics frontier. The company’s mission is to create ultra-efficient next-generation electronics, ultrafast optical networks and groundbreaking advances in pharmaceutical research. Under the leadership of co-founder and CEO Joshua Western, Space Forge is changing the game on crystal growth. They’re using the microgravity environment of space to take their novel approach to the next level.
In December, Space Forge powered up an orbital furnace on its ForgeStar-1 satellite, generating an uninterrupted cadence of super-hot plasma. This unique flying furnace produces perfectly designed seed crystals for optimized substrates. It leverages wide bandgap materials such as gallium, aluminum nitride, and silicon carbide that are key to the next generation high-performance power devices. To do this the company is taking advantage of the unique conditions in space. Their aim is to grow superconductor crystals that would increase electronic efficiency dramatically.
As mentioned previously, later this year, the new ForgeStar-1 satellite will deploy that new Revolutionary Atmospheric Entry Shield during its atmospheric de-orbit maneuver. This is an important move toward realizing its mission. Not without a bang—the satellite will eventually die when it re-enters Earth’s atmosphere. Space Forge estimates recovering a few kilograms of space-grown crystals in its next follow-up mission. The launch of this mission, next year as scheduled, now has taken on urgency and great significance.
The Promise of Microgravity
Additionally, the microgravity environment aboard the ForgeStar-1 is an ideal setting to study crystal growth. As Joshua Western explained, the lack of gravity creates uniform conditions that lead to more ideal crystal formation. He explains that on Earth, nitrogen acts as a brake on the growth process at levels as low as 10 to the -11. In contrast, in space, above 500 kilometers altitude, nitrogen is only at 10 to the -22.
“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
Notable improvements in quality and precision might produce better materials, with experts predicting that crystals grown in space show much higher electron mobility by as much as 300%. According to E. Steve Putna, executive director of the Texas A&M Semiconductor Institute, this new increased mobility has the potential to unlock transformative improvements. He proposes that it should increase switching efficiency 20 to 40 percent higher than Earth-grown equivalents.
Even as the potential of microgravity dazzles, some experts are calling for a more sober approach. Anne Wilson doesn’t think the microgravity route to bulk material manufacturing is feasible. She does think there’s untapped potential for the technology to be used in niche, targeted applications.
“However, niche materials for specific applications might be worth the investment.” – Anne Wilson
The Future of In-Orbit Manufacturing
Space Forge isn’t the only player trying to unlock the possibilities of in-orbit manufacturing. This surge of investment and opportunity has some experts predicting that the market will eclipse $28.19 billion by 2034. From 1973 to 2016, NASA researchers did grow about 160 semiconductor crystals in microgravity. A new meta-analysis, published in the journal Nature, demonstrates that this work has already set the stage for future breakthroughs.
Using space-grown materials, maintenance-driven energy consumption could be reduced by orders of magnitude when dealing with large, distributed infrastructure deployments like 5G towers. In fact, based on his work, Joshua Western estimates energy consumption reductions of up to 50 percent. These innovations have the potential to be game-changers for AI data centers where cooling costs are major chokepoints.
“There is potential for significant energy savings, perhaps as much as 50 percent within large infrastructure installations such as [5G] towers.” – Joshua Western
Additionally, advancements in yield rates for expensive components such as exotic high-end processor chips would render space-grown substrates financially advantageous. E. Steve Putna addresses the crux of the issue. If one substrate increases the yield of a $10,000 processor from 50 percent yield to 90 percent yield, the launching cost is less than a small fraction of the total value it creates.
“If a space-grown substrate increases the yield of a $10,000 high-end AI processor from 50 percent to 90 percent…the launch cost becomes a negligible fraction of the total value created.” – E. Steve Putna
Challenges Ahead
Space Forge is thus understandably buoyed by these developments. Yet, it continues to grapple with challenges in scaling up production and creating commercially viable, space-grown materials. As costs associated with space exploration decrease, they still do not keep pace with the declining costs of traditional wafer production.
As NASA’s Matt Francis puts it, blasting materials into space was once the no-brainer choice when costs were high. Recent trends add a complicated twist to this narrative.
“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
Now, despite these broader hurdles, Space Forge is not deterred in its mission. The company is convinced that customized and adaptable materials can be produced in space to serve unique applications across different industries. This innovation is just a glimpse of what’s to come.