A Comprehensive Review of Additive Manufacturing for Space Applications: Materials, Advances, Challenges, and Future Directions

Additive manufacturing (AM) is revolutionizing space exploration and manufacturing by addressing unique challenges in weight reduction, material optimization, and on‐demand production. This review examines the current advances and future directions of AM for on‐Earth and in‐space applications. The study highlights the role of AM in producing lightweight, high‐performance components for satellites, rockets, and space habitats, leveraging technologies such as powder bed fusion, directed energy deposition, binder jetting, sheet lamination, and material extrusion. Key applications include the development of propulsion systems, structural components, and thermal management devices optimized for the harsh conditions of space. In‐space manufacturing is explored as a pivotal innovation, enabling the on‐demand production of tools, components, and infrastructure in microgravity environments, reducing launch costs and enhancing mission scalability. Challenges such as material defects, anisotropic properties, and residual stresses are discussed alongside strategies for mitigation, including real‐time monitoring and advanced post‐processing techniques. The review also emphasizes the ethical, regulatory, and sustainability considerations of AM for space exploration, addressing issues of resource utilization and environmental impact. Furthermore, it uniquely integrates advancements in artificial intelligence‐driven process control, in situ resource utilization, and sustainability aspects of AM for space missions.