Material Tests for Space
18.06.2025
Materials for space must withstand extreme conditions in aerospace technology: Vacuum, strong temperature fluctuations and mechanical stresses act simultaneously on components and structures. Conventional test methods quickly reach their limits here. With the NextSpace TestRig from the University of Glasgow, a newly developed test method is now closing this gap. Funded by the British Space Agency, the test platform, which was developed by Dr Gilles Bailet and his team, enables realistic simulations for the qualification of materials and components for use in space - and also provides exciting impetus for applications on Earth.
Why conventional material tests are not sufficient for space travel
Dr Bailet, what was the motivation behind the development of the NextSpace TestRig?
Gilles Bailet: The space industry is rapidly adopting advanced materials and additive manufacturing, but we lack realistic testing methods to understand how these materials behave in the actual space environment. Traditional qualification methods often ignore the extreme conditions found in orbit or on the Moon—especially the combined effects of ultra-high vacuum and thermal cycling. The NextSpace TestRig, funded by the UK Space Agency, was developed to close this gap. Our goal was to create a ground-based platform capable of simulating space-like environments while applying mechanical loading, to better predict how materials perform in mission-critical scenarios.
Which specific conditions can be simulated within the NextSpace TestRig – and why are they so crucial for material testing?
Bailet: The TestRig, hosted within our NextSpace TestRig, can simultaneously simulate ultra-high vacuum (~10⁻⁶ mbar) and extreme thermal cycling (−100°C to +200°C) while performing real-time mechanical testing (up to 20,000 Newton force). This combination is crucial because many materials—especially polymers and composites—undergo significant changes in fracture strength, stiffness, or failure modes under such conditions. In one test, we observed a 43% reduction in fracture strain for a 3D-printed polymer (Nylon PA12) when tested in vacuum versus ambient conditions. These effects simply aren’t visible in traditional lab environments, yet they’re critical for designing safe and reliable components for space missions.
3D-printed polymers and metallic materials at the centre of space tests
What types of materials/plastics or components are typically tested – and what applications are they intended for?
Bailet: We’ve tested a range of additively manufactured polymers, such as PA12, and are now expanding to metallic materials including Inconel and titanium alloys. These materials are commonly used in satellite structures, antenna supports, thermal control components, and lightweight mechanical parts. Many of the tests are focused on flight-ready geometries, helping space companies refine their qualification data and reduce overdesign. We are also working closely with international partners who are exploring ISRU (In-Situ Resource Utilisation) and 3D printing using regolith-derived materials for lunar infrastructure.
- The NextSpace TestRig simulates ultra-high vacuum, extreme temperature fluctuations and mechanical loads - simultaneously.
- Polymers such as PA12, metals such as Inconel and titanium alloys are being tested - for satellites, antenna supports and thermal components for future applications on the moon.
- A test on 3D-printed nylon PA12 showed that the elongation at break was reduced by 43% in a vacuum compared to normal laboratory conditions.
Additive manufacturing as a key technology for autonomous production in space
What role does 3D printing play in the context of space materials, particularly with regard to autonomous production in space?
Bailet: 3D printing—or additive manufacturing—is central to the vision of autonomous in-space manufacturing (ISAM). It allows us to produce components directly in orbit or on the Moon, reducing reliance on expensive and limited Earth-to-space logistics. But to make ISAM viable, we need confidence that printed materials will behave as expected under space conditions. Our TestRig helps provide that assurance. It also supports future plans for in-situ mechanical characterisation, where testing equipment itself could be miniaturised and deployed in orbit or on the lunar surface to validate structures in real time.
How can insights from the TestRig be transferred to industrial applications on Earth – for example, in the field of high-performance materials?
Bailet: There’s strong potential to transfer what we learn from space-grade material testing to high-performance Earth-based industries. For example, sectors like aerospace, nuclear, deep-sea, and energy often deal with similarly harsh conditions—extreme heat, vacuum, radiation, or aggressive chemicals. Our methods help characterise how materials degrade under coupled stresses, which is especially relevant for safety-critical components or new additive manufacturing techniques. We're already seeing interest from industrial partners exploring next-gen polymers and composites for lightweight, mission-critical applications on Earth.
Next steps: miniaturised test systems for use in space
What are the next steps? Are there already specific applications or planned tests involving new materials or components?
Bailet: Building on the success of the NextSpace Testrig, we’re now planning to miniaturise the system for use in orbit and, eventually, on the Moon. At the same time, we’re eager to support other actors in the field to ensure that In-Space Manufacturing (ISM) becomes a safe and sustainable endeavour across the industry. Additionally, we’ve joined the Scottish Enterprise High Growth Spin-Out Programme to commercialise our own in-space manufacturing technologies, aimed at 3D printing functional structures like antennas and solar panels directly in orbit—a step that could significantly enhance spacecraft capabilities and mission flexibility.
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Editor: Simone Ernst | K-Mag
Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry.
At a glance
The NextSpace TestRig enables realistic material tests for use in space by combining vacuum, extreme temperatures and mechanical loads. For 3D-printed materials such as nylon PA12 in particular, it shows how much their properties can change in space. Polymers and metals that are to be used in satellite structures and future moon missions are among the materials being tested.
Dr. Gilles Bailet
The dedicated aerospace engineer (Power & Energy Systems) and lecturer in aerospace engineering, additive manufacturing at the University of Glasgow, develops 3D printing processes for extreme environments such as space. One current focus is on utilising local resources such as moon dust to manufacture materials in space.