Space Forge Secures $30M Series A Funding for In-Space Chip Material Production

The Growing Demand for Semiconductors and Material Limitations

The need for semiconductors is rapidly increasing, driven by advancements in areas like artificial intelligence and electric vehicles. However, the traditional material, silicon, is approaching its performance limits.

Developing more efficient chips necessitates exploring novel materials, those considerably rarer than sand. A potential solution lies beyond Earth – in space.

Space Forge: Manufacturing in Microgravity

Space Forge, a startup based in Cardiff, Wales, has secured £22.6 million (around $30 million) in Series A funding. Their goal is to manufacture wafer materials directly in space.

The unique conditions of the space environment offer unprecedented opportunities for material science.

Reduced Defects Through Space-Based Crystal Growth

Space Forge previously received funding for a project with BT (formerly British Telecom). This project aims to assess the benefits of space-grown crystals in reducing the energy consumption of 5G towers.

Crystals cultivated in space exhibit fewer defects due to weightlessness and other factors. This reduction in imperfections translates to improved energy efficiency in devices.

Feasibility and Historical Context

The concept of manufacturing chips in orbit isn't new; its viability has been understood since the 1970s, as CEO Joshua Western explained to TechCrunch.

“We are building upon approximately half a century of research demonstrating not only the possibility but also the significant advantages of this approach,” Western stated.

Enhanced Performance and Applications

The primary benefit lies in producing crystals and advanced semiconductor materials with fewer flaws and superior performance characteristics.

These enhanced materials are particularly valuable for demanding applications like quantum computing and defense systems.

Strategic Partnerships and Funding

The dual-use nature of this technology – serving both commercial and defense interests – explains the NATO Innovation Fund’s leadership in Space Forge’s Series A round.

Furthermore, the partnership with major U.S. defense contractor Northrop Grumman underscores the strategic importance of this venture.

Leveraging Existing Infrastructure

Space Forge is strategically focusing on integration rather than complete verticalization. The company will not be developing its own rockets.

Instead, they are relying on established space launch providers, viewing launch capabilities as a “solved problem,” according to Western.

The Challenge of Implementation

While individual components may be considered “solved problems,” integrating them – from chip fabrication to safe return from space – presents significant challenges.

Western acknowledges the difficulty, responding to questions about the company’s competitive advantage with a direct: “How bloody hard is it to do?!”

Adapting to the Space Environment

Successfully utilizing space’s unique environment requires overcoming harsh conditions, including extreme temperatures and microgravity.

“The principles of physics provide the solutions, and engineering is the process of realizing them,” Western concluded.

A Novel Approach to Material Return from Orbit

The progression of engineering necessitates bridging the divide between groundbreaking innovation and technologies that are commercially feasible. Unlike the capsule-based return systems exemplified by the Apollo program, Space Forge employs a unique method for bringing materials back to Earth, described as a “Mary Poppins from space” approach.

As Western clarified, this involves deploying a device resembling a high-grade umbrella, engineered for space conditions, which facilitates a controlled descent back to the planet’s surface.

A primary focus for Space Forge is the development of innovative return technologies. Beyond its thermal protection system, named Pridwen – a reference to Arthurian legend – the company has created Fielder, a specialized net designed to safely recover returning satellites and ensure gentle landings in water.

These initiatives have received support from both the U.K. Space Agency and the European Space Agency, with the U.K. continuing its membership in the latter despite Brexit.

Space Forge aims to establish a comprehensive return infrastructure throughout Europe, and progress is being made towards this goal. The company recently inaugurated an office in Portugal, specifically on the island of Santa Maria in the Azores.

This location is ideally suited for satellite recovery operations within mainland Europe and represents a crucial step in demonstrating the scalability of this approach to potential European collaborators.

The increasing availability and affordability of both launch and return technologies have been instrumental in the emergence of in-space manufacturing startups, with potential applications extending to areas like pharmaceutical research and telecommunications hardware. However, their long-term success hinges on reducing costs or securing clients willing to pay a premium for these services.

Current geopolitical shifts may assist Space Forge in attracting a larger client base. Western, alongside his co-founder and CTO Andrew Bacon, previously held positions at Thales Alenia Space, a joint venture between Thales and Leonardo.

However, the need extends beyond defense, as concerns grow across Europe regarding dependence on semiconductor supplies originating from Taiwan.

Resilient supply chains are critical. “We urgently need a resilient, homegrown supply of the next-gen supermaterials required for the future of compute. We also need this homegrown chip supply to be produced sustainably,” stated Daria Saharova, general partner at World Fund.

The climate tech venture capital firm, which participated in both Space Forge’s seed and Series A funding rounds, is investing in Space Forge’s positioning as a “carbon negative technology” with the potential to mitigate climate change.

It’s important to note that these emissions savings are yet to be validated on a large scale and are contingent upon widespread commercial adoption to effectively offset mission-related emissions.

Space Forge is still preparing for its inaugural mission. Their initial attempt was unsuccessful, concluding after just six and a half minutes when a launch anomaly occurred during Virgin Orbit’s Cornwall launch in 2023, resulting in the loss of all payloads, including Space Forge’s ForgeStar-0 satellite.

Bolstered by its recent funding, the company is now accelerating the development of its newest spacecraft and preparing for the launch of its ForgeStar-1 demonstrator later this year, alongside Pridwen.

In a playful nod to a popular science fiction franchise, Space Forge announced the mission’s official name – “The Forge Awakens” – on May 4th.

Anna Heim attended a World Fund event where her travel expenses were covered by the firm, and subsequently interviewed Joshua Western and Daria Saharova; this article represents her independent reporting.