Space Forge Achieves World First: Produces Plasma in Orbit for Novel Semiconductor Manufacturing in Space
The Dawn of In-Orbit Manufacturing: Space Forge’s Breakthrough in Plasma Production
In a groundbreaking development for the future of manufacturing, UK-based start-up Space Forge achieved a significant milestone by producing plasma in orbit aboard its ForgeStar-1 satellite. This world-first achievement marks a pivotal step toward the company’s vision of revolutionizing semiconductor manufacturing in space.
A New Frontier for Manufacturing
Launched in June 2025, the ForgeStar-1 satellite has been the cornerstone of Space Forge’s ambitious plans. In December of the same year, this microwave oven-sized craft ignited its miniature furnace for the first time, generating plasma at an astonishing temperature of 1,832 degrees Fahrenheit (1,000 degrees Celsius). This plasma will play a crucial role in the future production of super-efficient materials in the unique environment of weightlessness.
Joshua Western, CEO and co-founder of Space Forge, stated, “Generating plasma on orbit represents a fundamental shift. It proves that the essential environment for advanced crystal growth can be achieved on a dedicated, commercial satellite — opening the door to a completely new manufacturing frontier.”
Semiconductors: The Future of Electronics
Founded in 2018, Space Forge plans to use similar furnace technology on future satellites to produce novel semiconductors directly in the weightlessness of space. Until now, such experiments were limited to the International Space Station (ISS).
The recent plasma demonstration confirms that the extreme conditions required for gas-phase crystal growth, a key component of semiconductor production, can now be created and controlled on an autonomous platform in low Earth orbit. This achievement establishes ForgeStar-1 as the first-ever free-flying commercial semiconductor manufacturing tool in space.
The Advantages of Space-Grown Semiconductors
The absence of gravity in space allows atoms in semiconductors to align with remarkable precision, resulting in a material that outperforms anything produced on Earth. According to Space Forge, this improved efficiency could lead to reductions in energy consumption for electronic devices by up to 60%.
These advanced semiconductors, using rare materials such as gallium nitride, silicon carbide, or diamond, hold tremendous potential for future telecommunications systems, electronic devices, and next-generation computers.
Looking Ahead: Future Missions and Innovations
While the current mission of ForgeStar-1 focuses on testing its orbital factory equipment, the satellite is expected to deorbit and burn up in the atmosphere later this year. Before its decommissioning, it will conduct additional experiments to analyze the behavior of the generated plasma in microgravity and gather valuable data for future missions.
Space Forge recently secured a Series A funding round of £22.6 million ($30.5 million), enabling the development of its successor, ForgeStar-2. This upcoming spacecraft will be equipped with a novel heat shield to ensure safe atmospheric return and transport of its valuable semiconductors back to Earth.
Conclusion
The successful production of plasma in orbit represents more than just a milestone for Space Forge; it opens a world of possibilities in semiconductor manufacturing. With further research and development, this innovative approach could redefine electronic technologies and lead us toward a more efficient, sustainable future. Stay tuned for more updates as Space Forge continues to advance its mission to change manufacturing as we know it!