Space Forge generates plasma for LEO semiconductor material production

TAMPA, Fla. — Space Forge said Dec. 31 it generated plasma aboard its first satellite, a milestone the British startup says shows it can create and maintain conditions needed to produce valuable semiconductor materials in low Earth orbit (LEO).

“Generating plasma on orbit represents a fundamental shift,” said Space Forge cofounder and CEO Joshua Western, “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.”

Few details were shared about the plasma conditions created aboard ForgeStar-1, which launched on a SpaceX rideshare mission in June. Space Forge said the demonstration is a first for a commercial free-flying satellite, outside a space station environment.

The startup next plans to run a series of tests to map plasma behavior in microgravity to guide the design and operation of future satellites, which would aim to return materials to Earth.

Space Forge ultimately plans to produce materials in space such as gallium nitride, silicon carbide, aluminium nitride and diamond, used in applications ranging from power electronics and communications to defense and high-performance computing. The startup argues that producing these materials on Earth can be limited by defects and contamination introduced during growth, whereas the microgravity and ultra-high vacuum in space enable cleaner crystal formation.

Unlike the International Space Station, where manufacturing experiments compete for time, space and operational constraints in a shared, crew-tended environment, Space Forge’s dedicated satellites would be built around autonomous manufacturing processes. The company says this approach better supports repeatable, scalable production than experiments hosted on multipurpose platforms, including future commercial space stations.

While ForgeStar-1 is destined to burn up in the atmosphere, it is equipped with a proprietary heat shield called Pridwen. Space Forge has said it aims to test Pridwen on the satellite, alongside on-orbit aerodynamic control, for a controlled demise.

Space Forge ultimately aims to combine orbital crystal growth with terrestrial processing to complement existing supply chains.