Space Forge: Pioneering Reusable On-Orbit Manufacturing in the UK
Introduction
Space Forge, a Cardiff-based aerospace startup founded in 2018 by Joshua Western and Andrew Bacon, is at the forefront of revolutionizing space-based manufacturing. The company focuses on developing reusable, returnable satellites—ForgeStar—that utilize the unique conditions of low Earth orbit (LEO) to produce advanced materials unattainable on Earth. By leveraging microgravity, vacuum, and extreme temperatures, Space Forge aims to create ultrapure semiconductors and alloys, offering significant advancements in various industries, including telecommunications, quantum computing, and pharmaceuticals.
Technological Innovations
ForgeStar Platform
The ForgeStar satellite is central to Space Forge’s mission. Each vehicle comprises an orbital module and a microgravity capsule, operating at an altitude of approximately 300 miles for periods ranging from one to six months. These satellites are designed for reentry, enabling hardware and manufactured materials to be recovered and refurbished, promoting sustainability in space operations. (Wikipedia)
Pridwen Reentry System
A significant challenge in space-based manufacturing is the safe return of materials to Earth. Space Forge has developed the Pridwen heat shield, a novel thermal protection system that enables the satellite’s safe re-entry and reuse. This technology underpins the company’s ambition to develop returnable space platforms, driving sustainable practices in orbital manufacturing. (SpaceDaily)
Microgravity as a Service
Space Forge offers “Microgravity-as-a-Service,” providing access to the unique environment of space for various applications. This approach allows organizations to conduct experiments and produce materials in microgravity, which can lead to breakthroughs in areas such as clean energy, secure communications, and advanced materials. (spaceforge.com)
Milestones and Achievements
ForgeStar-1 Launch
In June 2025, Space Forge successfully launched ForgeStar-1, the UK’s first in-space manufacturing satellite, aboard SpaceX’s Transporter-14 mission. Built entirely in Wales, ForgeStar-1 is designed to utilize the conditions of low Earth orbit to manufacture advanced semiconductor components for AI data centers, quantum computing, and military applications. While primarily serving as a proof-of-concept, the satellite aims to test key in-space fabrication technologies and pave the way for future missions. (Tom’s Hardware)
Series A Funding
In May 2025, Space Forge secured £22.6 million in Series A funding, marking the largest such investment in UK space technology history. The funding round was led by the NATO Innovation Fund, with participation from the National Security Strategic Investment Fund (NSSIF), World Fund, and the British Business Bank through its Regional Angels Programme. (SpaceDaily)
UK Civil Aviation Authority License
In 2024, Space Forge received a license from the UK Civil Aviation Authority to launch ForgeStar-1, the country’s first in-orbit manufacturing satellite. This milestone underscores the UK’s commitment to advancing space-based manufacturing capabilities and positions Space Forge as a leader in the field. (advancedmaterialsshow.com)
Applications and Impact
Semiconductor Manufacturing
Space Forge’s platform enables the production of ultrapure semiconductor crystals in space, offering enhancements in thermal conductivity and electron mobility. These improvements can lead to more efficient power electronics, telecommunications devices, and quantum computing components. (spaceforge.com)
Pharmaceuticals
The unique environment of space allows for the production of pharmaceutical compounds with higher purity and efficacy. Space Forge’s technology could facilitate the development of advanced drugs and treatments, contributing to global healthcare advancements.
Clean Energy
By manufacturing materials with superior properties, Space Forge’s platform can support the development of more efficient renewable energy technologies, such as solar cells and energy storage systems, aiding in the transition to a sustainable energy future.
Future Prospects
Looking ahead, Space Forge plans to expand its operations with the development of ForgeStar-2, a next-generation returnable manufacturing satellite. The company aims to mass-produce up to 100 satellites annually, positioning itself as a key player in the emerging field of space-based manufacturing. (Tom’s Hardware)
Technological Innovations
ForgeStar Satellites
At the core of Space Forge’s operations are its ForgeStar satellites. These are designed to operate in low Earth orbit (LEO) for extended periods, utilizing microgravity to manufacture high-performance materials. The first operational satellite, ForgeStar-1, was launched in June 2025 aboard SpaceX’s Transporter-14 mission. Developed entirely in Wales, ForgeStar-1 aims to produce advanced semiconductor components for AI data centers, quantum computing, and military applications. (Tom’s Hardware)
Pridwen Heat Shield
A significant challenge in space-based manufacturing is the safe return of materials to Earth. Space Forge has developed the Pridwen heat shield, a novel thermal protection system that enables satellites to re-enter the Earth’s atmosphere safely. This technology is crucial for the recovery and reuse of manufacturing platforms. (AGN)
Case Studies and Applications
Semiconductor Manufacturing
Space Forge’s platform enables the production of ultrapure semiconductor crystals in space. These materials have enhanced thermal conductivity and electron mobility, leading to more efficient power electronics and telecommunications devices. The unique conditions of space allow for the growth of larger crystals with fewer defects, which is challenging to achieve on Earth. (factoriesinspace.com)
Pharmaceutical Development
The microgravity environment of space facilitates the production of pharmaceutical compounds with higher purity and efficacy. Space Forge’s technology could enable the development of advanced drugs and treatments, contributing to global healthcare advancements.
Clean Energy Technologies
By manufacturing materials with superior properties, Space Forge’s platform can support the development of more efficient renewable energy technologies, such as solar cells and energy storage systems. This contributes to the transition to a sustainable energy future.
Industry Impact and Future Prospects
Space Forge’s innovations position the UK as a leader in the emerging field of in-orbit manufacturing. The company’s advancements in reusable satellite technology and controlled re-entry systems set a precedent for sustainable space operations. Looking ahead, Space Forge plans to expand its operations with the development of ForgeStar-2, a next-generation returnable manufacturing satellite. The company aims to mass-produce up to 100 satellites annually, positioning itself as a key player in the global space economy. (Tom’s Hardware)
Conclusion
Space Forge exemplifies the UK’s commitment to leading in the global space economy through innovation and sustainable practices. By harnessing the unique conditions of space, the company is poised to transform industries ranging from telecommunications to pharmaceuticals. As the UK continues to invest in space capabilities, Space Forge stands at the forefront of a new era in aerospace innovation.