European Space Agency (ESA) logo
European Space Agency

Application-Led Material Development for Future Spaceflight

Context

The European Space Agency (ESA) explores advanced technologies and materials to support future space missions. Within its European Astronaut Centre (EAC), researchers investigate how additive manufacturing can support rapid prototyping and potential in-space manufacturing.

Developing new materials for these applications requires the ability to experiment quickly and test ideas using small quantities of polymers 

ESA Spaceship Team
“3devo’s extrusion system has let us use the ‘prototyping mindset’ – making more iterations, but with less resources. It gives us the freedom to understand material properties much better, as compared to just buying filament off the shelf. We now have more control over the whole process, and the flexibility to use exotic materials.”
 
- Stefan Siarov, Spaceship EAC Team Member at ESA/EAC

The Challenge

ESA researchers needed a way to experiment with new materials for space applications without relying on external filament suppliers. Traditional workflows limited their ability to test custom formulations and slowed down experimentation.

The goal was to create a workflow that would allow scientists to develop and test materials internally while maintaining flexibility for rapid iteration.

ESA Prototyping Material

The Approach

ESA implemented an in-house workflow that allows researchers to develop and test new filament materials directly within their laboratory environment.

By producing filament internally, scientists can experiment with different polymer formulations and evaluate their performance through rapid prototyping.

This approach enables researchers to explore novel materials and composites while maintaining full control over the development process.

ESA PEKK Filament Spool