Orbital Matter and EnduroSat Target 2028 for In-Orbit 3D Manufacturing
Warsaw-based startup Orbital Matter and Bulgaria's EnduroSat are partnering to 3D print a 5-meter, 5 kW solar array in space by 2028, aiming to bypass the physical constraints of launch vehicle fairings.
Manufacturing Without Constraints
In a move to redefine orbital architecture, Polish startup Orbital Matter has announced a partnership with EnduroSat for a 2028 mission dedicated to in-space manufacturing (ISAM). The mission aims to deploy a 5 kW solar array utilizing support structures 3D-printed directly in the vacuum of space. According to Payload, the mission serves as a critical validation of technology designed to move beyond the limitations of traditional deployable structures.
Breaking the Fairing Barrier
Currently, spacecraft design is dictated by the volume constraints of launch vehicle fairings, requiring complex folding mechanisms that add mass and risk. Orbital Matter CEO Jakub Stojek notes that systems are currently designed for the stresses of launch rather than the requirements of orbital operations. By printing rigid booms in situ, operators can bypass these geometric restrictions.
This upcoming mission builds on the recent Replicator 2 demo. Launched via SpaceX, the Replicator 2 hardware successfully printed a 32.5 cm bonded structure in orbit using liquid material hardened by UV light. While the initial attempt faced layer-bonding issues, a firmware update allowed the team to successfully deploy a partial solar blanket along a printed boom.
The Path to Orbital Data Centers
The 2028 flight will scale this technology to a 5-meter boom supporting a 5 kW array. This capability is a prerequisite for the emerging orbital edge-computing market. EnduroSat CTO Victor Danchev emphasized that future AI-driven orbital data centers will require hundreds of kilowatts—power levels unattainable with current folding solar technology.
Beyond solar power, Orbital Matter intends to adapt its printing technology for lunar and Martian infrastructure. To support this roadmap, the seven-person firm is currently seeking new financing to expand its production facilities and engineering team.