Welsh Startup Space Forge Secures Major Milestone for Space Manufacturing

A Cardiff-based startup, Space Forge, is set to revolutionise advanced manufacturing by launching an innovative robotic factory into space. The company’s oven-sized ForgeStar-1 satellite is scheduled to be sent into orbit later this year from the US after securing a critical licence from the UK’s Civil Aviation Authority. This marks a significant milestone in developing space-based manufacturing capabilities.

Space Forge aims to utilise the unique conditions of low-earth orbit, such as near-zero gravity, extreme temperatures, and vacuum environments, to create high-purity crystals. These materials have the potential to advance semiconductors, drugs, and metal alloys – innovations that could outperform traditional earth-based manufacturing processes and applications significantly.

The company previously faced a major setback when the 2023 launch attempt by Virgin Orbit – Sir Richard Branson’s venture – failed, resulting in the loss of Space Forge’s payload. The satellite crashed into the ocean, highlighting challenges for UK-based space launches. Consequently, Space Forge opted for its upcoming test launch to take place overseas, emphasising the need for cost-effective and reliable launching options.

Joshua Western, the company’s chief executive, outlined why low-cost reliability is critical for the UK’s developing spacetech sector. Although the company is leveraging a US-based launch partner for the moment, Western expressed enthusiasm for domestic launches in the future, noting the economic and logistical efficiencies of operating closer to home.

The experimental launch later this year seeks to test the viability of in-orbit manufacturing, alongside stress-testing the heat shield designed for the satellite’s return to Earth. This mission acts as a crucial proving ground, opening doors for full-scale production-ready factories to begin operations in 2026, marking a new phase in industrial innovation.

Despite the loss of momentum for UK-based launches after Virgin Orbit’s failed 2023 attempt, collaborations between British and German space industries suggest a revival. Plans for joint satellite launches from the SaxaVord spaceport in Shetland signal progress for Britain’s role in the global space manufacturing arena. Western reaffirmed that if the UK meets the necessary affordability and reliability standards, Space Forge would readily champion domestic launches in future missions.