In Space Dry Printing Multimaterial Electronics and Semiconductor Devices

The In Space Dry Printing Multimaterial Electronics and Semiconductor Devices project will test a dry multimaterial printing technology for electronics and semiconductor devices in microgravity. This technology is intended to support in-space manufacturing infrastructure and capabilities for printing electronics and semiconductor devices that enable “in-space for space” and “in-space for Earth” manufacturing needs. The potential advantages of microgravity and the vacuum environment of space for this technology makes it a useful capability for in-space electronics manufacturing and could enable future space commercialization for Earth applications. 

Problem Statement 

The state-of-the-art conventional semiconductor device manufacturing industries currently involve multiple wet processes such as photolithography, etching, and cleaning. It requires extensive and expensive infrastructure for operation, and the wet processes are challenging or often impossible to perform in microgravity. Additively manufactured electronics (AMEs) or printed electronics are therefore becoming attractive solutions for space and distributed manufacturing needs. However, the current printing technologies are liquid-based, which besides the limited sources for printing materials, makes them challenging to use in the microgravity of space. This inkless printing technology intends to eliminate the detrimental effects of ink formulation, ink-associated contamination, and post-processing requirements in current technologies. 

Technology Maturation 

In collaboration with NASA, the design and printing of various materials using this dry printing technique have been tested on Earth. To transition the technology into an in-space manufacturing capability, its operation should be tested under microgravity. The parabolic flight test is expected to provide researchers with the opportunity to test the technology operation under microgravity and prepare it for the next tests in low Earth orbit (LEO) and ultimately on the lunar surface.

Summary of May 9, 2025 Flight Test
During this flight campaign, the team successfully demonstrated a dry multimaterial printing system in microgravity, utilizing an ablation laser to generate nanoparticles from silver and copper targets. These nanoparticles were then printed into precise patterns during each parabola of the Zero-G flight. The experiment was designed to maximize printing efficiency within the 20-25 second Zero-G windows, achieving successful line patterns with high precision. This achievement marks an important milestone in developing innovative material printing techniques for space applications, with a focus on producing durable, high-quality materials in microgravity. The team is now focused on conducting extensive post-flight analysis to assess the performance and long-term stability of the printed samples.

- Efficiency: Enables self-contained environmentally friendly low/no-waste manufacturing of electronics and semiconductor devices 
- Flexibility: Allows greater design and operation flexibility than conventional electronic and semiconductor manufacturing technologies 

Future Customers 
- In-space manufacturing of electronics and semiconductor devices for space exploration (e.g., crew health and space habitat monitoring sensors) and commercial use on Earth 
- Part of Space Technology Mission Directorate’s On Demand Manufacturing of Electronics project

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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