Space Forge is a London-based company, founded in 2018. Harnessing the one-of-a-kind conditions space affords, they’re making leaps and bounds in advanced electronics by utilizing the space to grow larger, purer crystals. In December, the company’s ForgeStar-1 satellite powered up its cutting-edge orbital furnace. This amazing device sent extreme hot plasma in a stream, which was specially shaped to generate the seed crystals. These crystals will be used as substrates for the growth of gallium and aluminum nitride. They are equally important for silicon carbide, which is a key enabler of high-performance power devices.
As with ForgeStar-1, the difference now is that these tests are not just experiments, but a progressive step towards real orbital manufacturing. Space Forge shows that it is possible to create and maintain the conditions required for the successful growth of superconductor crystals. In so doing, the company seeks to get past some of the challenges encountered while growing crystals on Earth. The satellite is specially designed to mitigate problems caused by gravity, which can negatively affect the crystallization process.
According to Joshua Western, co-founder and CEO of Space Forge, producing crystals in microgravity can offer a number of significant benefits. Sheppard noted that nitrogen concentration was much lower in space than on Earth. This gaseous hormone, in turn, can disrupt growth processes.
“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
“In space, above 500 kilometers altitude, it’s naturally present at 10 to the -22.” – Joshua Western
The first batch of crystals produced by this novel technique is well on its way back to Earth. A return follow-up mission is already planned for next year to return them home. That said, the ForgeStar-1 satellite is built with an end-of-life mechanism that will have it meet its demise on return trajectory.
Breakthrough in Orbital Manufacturing
Space Forge’s deployment of its orbital furnace is seen as a breakthrough in manufacturing techniques. As the company sees it, tapping into that unique microgravity environment is necessary to achieve the perfect (or near-perfect) semiconductor crystals. On Earth, gravity can cause distortion from uneven growth with the potential for defects. In microgravity we can achieve a more uniform deposition and high quality materials.
Western went into detail on that nearly impossible set of circumstances in a typical environment for crystal growth.
“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
Not only is it fun, it has the potential to massively improve defect control in semiconductor materials. We are just as much interested in realizing deep energy savings in their deployment. Western highlighted how much could be saved in a big way. They pointed out that these savings can balloon to as much as half in huge infrastructure deployments, such as 5G towers.
“Microgravity effectively prevents convection from taking place, so you get a continually uniform deposition area.” – Joshua Western
Space Forge is just one of a number of companies riding a growing wave of interest in the development that can be driven by materials created in space. These include innovations in ultra-efficient next generation electronics to paradigm shifts in pharmaceutical research. With the development of more affordable methods of launching materials into orbit, the hope for their space-grown counterparts is becoming an industry optimism.
Future Implications for Electronics and Beyond
Not everyone is a believer of the widespread application of this technology. The author Anne Wilson has been a long-time skeptic about the feasibility of mass-producing bulk materials in microgravity.
Still, she said there are certain niche materials that would be worth the investment in space manufacturing.
“I don’t think that microgravity is going to be ideal for the manufacture of bulk materials,” – Anne Wilson
Matt Francis provided fascinating details on the nuts and bolts of the economic side of producing wafers to create electronics. Reflecting on previous times when sending tangible materials into space was financially impossible, he continued.
As for the danger, he cited launch costs rapidly falling. They may not be falling fast enough to compete with the cost of production here on earth.
“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
The impact of Space Forge’s innovations could be tremendous. Dr. E. Steve Putna from NASA Ames pointed out an intriguing potential application—a space-grown substrate could increase the yield of top-of-the-line AI processors from 50 percent to 90 percent. It would allow quantum computers to function at higher temperatures, potentially even room temperature, upending the economic calculus.
With dozens more tests planned over the course of this year, Space Forge is clearly dedicated to taking crystal growth technology to the next level. For ForgeStar-1 satellite to operate successfully, it’s critical. Its effects will be far-reaching as it will help shape future missions and technologies aimed at leveraging space-based manufacturing.
“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
Looking Ahead
As Space Forge plans additional tests throughout this year, its commitment to advancing crystal growth technology remains strong. The successful operation of the ForgeStar-1 satellite will play a crucial role in shaping future missions and technologies aimed at harnessing space for manufacturing.