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Completed TRL 4 (started at 4, targeting 5)
The Space Metal Processing System (SMPS) Microgravity Testing Through Parabolic Flight will support testing of two subsystems prior to SMPS/Modular Space Foundry (MSF) demonstration on the International Space Station. The MSF is designed to process metal in any gravity environment into rods, tubes, sheet metal, wire, metal propellant, and other products through casting, continuous casting, droplet printing, and other mechanisms. Designed for higher throughput and broader capabilities than the current Materials Science Laboratory Electromagnetic Levitator (MSL-EML, or EML), it uses electromagnetic induction to heat, melt, and manipulate metal for the purpose of changing its shape and/or its properties.
Problem Statement The SMPS innovation builds on technology of the EML currently running on the space station. The EML has been used for containerless processing of metals, alloys, and semiconductors on the station since April 2015 to study melting and solidification properties in microgravity. The MSF technology advances in-space metal processing for industrial purposes by enabling melting and manipulation of higher quantities of metal than the current EML, as well as providing continuous casting capabilities to make commercial products.
Technology Maturation The latest prototype MSF has previously been tested on parabolic flights. The expected outcome for these additional two flight tests is to validate key subsystems under microgravity conditions to de-risk future on-orbit testing and to deliver preliminary results that will help guide experimental parameters for testing on the space station.
Summary of May 8, 2025 Flight Test
CisLunar Industries completed its third parabolic flight to advance the TRL of its metal processing and contactless manipulation technologies for In-Space Manufacturing (ISAM) and Dynamic Space Operations. Through this campaign an aluminum billet was cast and the capability for contactless manipulation of metal objects was demonstrated under microgravity conditions. The electromagnetic manipulation experiment, known as Steer, was deployed as a free-flying experiment to isolate it from small aircraft movements and provide a clean microgravity environment. CisLunar Industries continues to pioneer metal processing and manipulation in microgravity with the goal to enable large-scale metal fabrication off-world.
Summary of November 5, 2024 Flight Test
As part of the NASA Flight Opportunities program, and on a second parabolic flight, CisLunar Industries successfully cast their first full aluminum billet under microgravity conditions. Additionally, an upgraded version of the contactless 3D molten metal manipulation system, known as steer, was tested in microgravity for the first time. These tests pave the way for an upcoming mission to the International Space Station, which will operate key components of a space foundry system that is aimed at enabling large scale fabrication in Earth orbit and beyond.
- Commercial advancement: Pursues commercial market for reuse of in-space materials
- Sustainable: Targets space debris removal/reuse
- Crosscutting: Offers generic capability for various application domains
- In-space servicing, assembly, and manufacturing
Future Customers
- Active debris removal
- In-situ resource utilization vendors
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This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.
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