Space Forge launches first manufacturing satellite
Space Forge has confirmed the successful launch and in-orbit communication with the UK’s first in-space manufacturing satellite, developed entirely in Wales.
Manufacturing ultra pure power materials in the vacuum and microgravity of space can potentially provide substrates for high performance, high efficiency devices, but there are of course significant challenges in returning the material safely to the surface. Space Forge has developed a number of key technologies for this which are being tested in this launch.
ForgeStar-1 launched aboard the SpaceX Transporter-14 rideshare mission from Vandenberg Space Force Base in California. The satellite successfully activated and made contact with the Space Forge Mission Operations Centre in Cardiff, UK.
This successful launch marks the completion of more than four years of design, testing and regulatory milestones following the loss of the ForgeStar-0 cubesat prototype in 2023. ForgeStar-1 was built and qualified in-house by Space Forge’s Cardiff team and is the first UK satellite to receive an in-space manufacturing licence from the UK Civil Aviation Authority.
The new satellite is 11 times larger than ForgeStar-0 but the development suffered from significant problems. Suppliers collapsed, and key components showed failure rates of over 80%. So the system was re-designed and brought in-house with Space Forge as the primary integrator.
- Forge Star raises £22.5m for space factory
- NATO equity fund backs Space Forge
- Space Forge teams with Northrup Grumman
After a system health check, the manufacturing equipment will be tested. While the satellite Is not intended to return to earth, Space Forge plan to test out the re-entry technology that will eventually bring these materials back to the surface. This includes the deployment of Pridwen, Space Forge’s proprietary heat shield; on-orbit aerodynamic control to steer and decelerate the satellite; and real-time orbital tracking paired with predictive re-entry mapping using the company’s Aether software.
Earlier this month the company last week signed a deal for clean room facilities in Swansea to accept the materials grown in the microgravity of low earth orbit, including ultra-pure wide bandgap materials gallium nitride (GaN), silicon carbide (SiC) and gallium oxide (Ga2O3) for power and RF applications.
“We’ve built and launched Britain’s first manufacturing satellite and it’s alive in orbit, that’s a massive technical achievement. Now, we take the next step: proving that we can create the right environment for manufacturing in space. This is the start of a new era for materials science and industrial capability,” said Josh Western, CEO and Co-founder of Space Forge.
ForgeStar-1 released into orbit
“This isn’t just another satellite – it’s a testament to British engineering and our commitment to developing in-space manufacturing technologies that can benefit life here on Earth,” said Dr Paul Bate, CEO of the UK Space Agency, which has previously supported Space Forge with funding
“ForgeStar-1 exemplifies how the UK space sector is pushing boundaries in sustainable space technology, with its ability to return to Earth for refurbishment and reuse. This approach aligns directly with our ambitions to develop environmentally responsible access to space while creating high-skilled jobs across the UK.
Power semiconductor analysis
Space Forge is also the first company to be physically hosted in the Centre for Integrative Semiconductor Materials (CISM) following a deal with the University of Swansea. It will use a dedicated clean room incubation bay and have access to a full suite of semiconductor processing and characterisation tools.
CISM is part of the CSconnected advanced semiconductor ecosystem in South Wales, Europe’s first cluster for advanced compound semiconductor manufacturing which includes Vishay at Newport, Microchip, KLA, and IQE.
“We are delighted to be the first incubation client at CISM, gaining access to their state-of-the-art clean room facilities and cutting-edge semiconductor tools,” said Alastair McGibbon, Head of Semiconductors at Space Forge.
“This partnership provides Space Forge with the critical infrastructure needed to advance our work in space-based manufacturing and terrestrial scale-up. With full access we’re now in an even stronger position to drive innovation – enabling us to continue to drive semiconductor manufacturing forward at pace.”
If you enjoyed this article, you will like the following ones: don't miss them by subscribing to :
