Revolutionary 3D printing technology takes space travel to a new level!

Revolutionary 3D printing technology takes space travel to a new level!

On March 11, 2025 at 10:15 a.m. CET, a sounding rocket successfully launched from the Esrange Space Center in Sweden. This launch was part of the European program REXUS (Rocket Experiments for University Students), which is supported by the German Aerospace Center (DLR) and the Swedish Space Agency SNSA. In this project, the Technical University of Berlin (TU Berlin) tested novel, 3D-printed fuel tanks for future space applications.

The team “BEARS e.V.” (Berlin Experimental Astronautics Research Student Team) had successfully applied to REXUS with its experiment and prepared for tests and installation of the experiment a week before the start in Kiruna. Five students were on site, while three more traveled for the actual start. A total of eight teams were present who carried out a variety of experiments with two sounding rockets during the mission.

Experimental approaches in weightlessness

The focus of TU Berlin was on the behavior of fuel in weightlessness, especially 3D printed fuel tanks. The researchers were able to carry out their tests during two minutes of weightlessness. Six different designs for so-called “Propellant Management Devices” (PMDs) were tested under weightless conditions. These new designs can only be produced using additive manufacturing processes, i.e. 3D printing.

The experiment, named “WOBBLE2” (Weightless Observation of Fluid Behavior with Berlin Liquid Guidance Experiment), observed the tanks filled with fluorescent water. Six cameras provided valuable data on the behavior of the fuel, which in weightlessness differs from usual behavior under normal conditions and poses significant challenges for the attitude control of a spacecraft.

The role of 3D printing in space travel

The use of 3D printing technology in space travel is trendsetting. This technology is becoming increasingly important for the production of prototypes and components, not only for launch vehicles and transport vehicles, but also for satellites and space stations. Current research is using 3D printed parts, primarily from materials such as aluminum and titanium, to develop lighter and more cost-effective solutions.

NASA sees great potential in additive manufacturing and is pursuing projects that also include applications on Mars and in asteroid mining activities. The focus is not only on on-site application, but also on the possibility of creating complicated components directly on site using 3D printers. Future developments could significantly benefit the entire space industry.

The TU Berlin project received support from the Society of Friends of TU Berlin as well as other companies such as APWORKS GmbH, which supported metal printing, and Sensirion AG, which helped with the purchase of sensors and travel costs. This example illustrates the interdisciplinary approach and collaboration in driving space innovation.