Mon, 03 August, 2026
TWI has been awarded a contract by the European Space Agency (ESA) and the UK Space Agency (UKSA) to develop a next-generation electron beam (EB) welding and additive manufacturing (AM) system.
The contract, awarded as part of the General Support Technology Programme (GTSP), will unlock new capabilities for in-space servicing, assembly and manufacturing (ISAM), enabling high-quality joining and manufacturing directly in orbit to support the future of sustainable space infrastructure.
About The Technology
The sophisticated EB system being developed at TWI will support both welding and AM with aluminium and titanium alloys. These materials are already widely used in aerospace due to their high strength-to-weight ratios, durability, and thermal stability, making them ideal for constructing highly durable, low-mass, resilient structures able to withstand the harsh conditions of space.
Although the vacuum and microgravity conditions of space can present challenges that differ significantly from terrestrial welding operations, the EB welding system is being designed to mitigate against in-space molten metal behaviour and thermal distribution challenges to ensure high-quality welds with strong structural integrity. This will be achieved with a co-axial wire feed system that is crucial for accommodating gaps between components, which are likely to arise when constructing large-scale assemblies in space.
The wire feed system will enable AM as well as welding, making it capable of assembly, fabrication and in-situ repairs, while the adoption of a co-axial system will reduce the electrical and energy requirements, dropping the voltage from 20 kV to 10 kV.
Because the system includes options for autonomous and semi-autonomous operation - which aligns with industry trends toward autonomous in-space infrastructure and assembly - it can adapt to unforeseen challenges in real-time, reducing astronaut workload, and ultimately lowering mission costs.
Applications
EB Technology offers a versatile solution for the welding, wire-fed AM and repair of large structures in space. This flexibility is essential for a range of applications, including the in-space construction of orbital stations, solar arrays, telescopes, antennas, reflectors, radars, very long booms, and radiation shields, as well as bases on the surfaces of the Moon and Mars. The EB system is being developed at TWI as a low-mass, high-efficiency tool, with a demonstrated capability in a vacuum environment. By enabling the direct fabrication of large structures beyond the capacity limits of current launch vehicles, this project represents a critical step toward achieving sustainable infrastructure in space.
Apart from its primary functions in welding and additive manufacturing, the technology has the potential to be adapted for a wide array of other in-space manufacturing applications such as X-ray inspection, cutting and recycling.
TWI’s experts will draw upon decades of knowledge in electron beam welding and AM, as well as experience of the exacting requirements of the space industry built up over a range of projects for the sector, to increase the technology readiness level (TRL) of the co-axial EB welding and AM system from 2 up to 5, providing a unique and innovative solution for ESA and the space industry.