Plasma-enabled additive manufacturing in space: Perspectives, innovative material processing technologies, and emerging challenges

Satellite technology is the cornerstone of space exploration. Recently, satellite constellations have emerged as an affordable and efficient way to expand the range of possible missions. Small satellites offer impressive capabilities and can be mass-produced and deployed. However, the long-term growth of the small satellite economy will depend on adopting sustainable product life-cycle management. This includes maximizing the efficiency and effectiveness of space operations by developing functional platforms for repair, servicing, and upgrading of assets after they have been deployed in space. Additive techniques, particularly those enhanced by the use of plasma, could become key tools in this endeavour as the use of charged particles may help overcome some of the challenges presented by the space environment, such as microgravity and extreme temperatures, reducing the risks and costs associated with repairs and upgrades. Our review examines the level of technological readiness of plasma-enhanced and plasma-enabled additive manufacturing technologies in view of their possible use for various in-space satellite repair and servicing tasks, concluding that it is sufficient to initiate its implementation in space. Looking towards the future, key obstacles and benefits of incorporating 3D plasma printing technology in both open space and microgravity environments are explored.