Additive Manufacturing in Space: Technologies, Flight Heritage, and Materials

Additive manufacturing (AM) is increasingly recognized as a critical enabler for sustainable space exploration, offering on-demand fabrication, reduced reliance on Earth-based resupply, and enhanced mission autonomy. Over the past decade, in-space AM has progressed from early polymer extrusion experiments aboard the International Space Station (ISS) to the demonstration of multi-material capabilities involving polymers, metals, ceramics, recycling systems, and in situ resource utilization (ISRU) concepts. This review provides a comprehensive synthesis of AM technologies developed for space applications, with emphasis on demonstrated flight heritage, process behavior under microgravity and vacuum conditions, and materials validated in orbit. The paper surveys major AM process families relevant to space, including fused filament fabrication, directed energy deposition, ceramic stereolithography, bioprinting, and closed-loop recycling systems. Key ISS-based platforms—such as the Additive Manufacturing Facility, Ceramic Manufacturing Module, and Refabricator—are reviewed to assess technological maturity and system-level integration. Materials performance across polymers, metals, ceramics, and regolith-based feedstocks is discussed, highlighting the influence of microgravity, thermal transport, and environmental exposure. By comparing in-space results with terrestrial and reduced-gravity studies, this review identifies consistent trends, critical limitations, and remaining knowledge gaps, providing a structured perspective on the readiness of in-space additive manufacturing for future orbital and deep-space missions.