UK’s Space Forge highlights orbital manufacturing breakthrough at DSEI 2025
At DSEI London, Welsh company Space Forge is outlining how its ForgeStar platform for in-orbit manufacturing and controlled re-entry could provide new materials and capabilities with potential applications in defence, energy and advanced technologies.
Space Forge has positioned itself as a developer of space-based advanced materials and return technology. At the show, it is presenting the case for using orbital conditions to produce high-performance materials that cannot be manufactured on Earth, with possible benefits for semiconductors, power systems and sensors.
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In-orbit manufacturing with ForgeStar satellites
The ForgeStar satellites are designed to make use of microgravity, vacuum and temperature extremes in orbit to produce semiconductor crystals and other specialist materials. Research cited by the company suggests such products could reduce carbon emissions in some industrial applications by up to 75 per cent.
The company is also testing systems for return and reuse. Its Pridwen shield is intended to enable satellites to re-enter the Earth’s atmosphere safely, allowing hardware and manufactured materials to be recovered and refurbished.
“In-orbit manufacturing allows us to deliver materials that drive progress on Earth, from cleaner energy to more secure communications,” said Joshua Western, CEO and Co-Founder of Space Forge. “By coupling this with controlled re-entry, we’re building a platform that’s both scalable and reusable.”
The company points to potential applications across semiconductors, quantum computing, defence technologies and renewable energy.
ForgeStar-1 licence and launch milestone for UK space
In 2024, Space Forge secured a licence from the UK Civil Aviation Authority to launch ForgeStar-1, the country’s first in-orbit manufacturing satellite. The mission, launched in June 2025, was a demonstration of material production processes and the Pridwen heat shield, providing proof of concept for future reusable platforms.
At 11 times the size of its 2023 ForgeStar-0 satellite, ForgeStar-1 marked a step-up in scale and capability.
The CAA described the licence as a milestone for the UK space sector. “The ground-breaking licence for the UK space sector paves the way for in-orbit manufacturing,” said Colin Macleod, Head of the UK Space Regulator.
With interest in orbital manufacturing increasing internationally, Space Forge is using DSEI to underline its role within the UK’s growing space industry and its plans to contribute to wider cross-sector applications.
