A company founded by “two individuals in a Cardiff garage” is preparing to launch a revolutionary space factory that could spark a new industrial era.
Space Forge will soon transport its prototype manufacturing satellite from an industrial park in the city to the US, where it will be launched into orbit aboard a SpaceX rocket.
Sky News was granted exclusive access to the company’s meticulously clean ‘clean room’ to witness engineers conduct final inspections.
Loaded with raw materials, ForgeStar-1 is set to produce a new breed of highly efficient semiconductor chips that are unattainable on Earth.
Joshua Western, one of the company’s co-founders, expressed, “This marks the beginning of a space-driven industrial revolution, moving away from Earth.”
Semiconductors are crucial components in nearly all electronic devices, traditionally made from silicon crystals that have limitations in performance.
This prototype satellite aims to create new raw materials for highly efficient semiconductor chips
However, in the microgravity and vacuum of space, it becomes feasible to form crystals from alternative chemical compounds, enabling computer chips to operate faster while consuming less energy.
“We can reduce energy consumption by over 50% in their deployment locations,” Joshua mentioned.
“In the UK alone, the potential energy cost savings amount to billions of pounds.
“This impacts not only consumer mobile data but also energy-intensive applications like artificial intelligence, quantum computing, and even everyday tasks such as ChatGPT.”
ForgeStar-1 is being inspected ahead of its upcoming launch on a SpaceX rocket
The prototype will trial the material-making process and has secured the first advanced manufacturing license in orbit from the Civil Aviation Authority. If successful, the subsequent mission will focus on producing pure crystals for high demand on Earth.
The company estimates that premium electronic materials made in space could be valued at up to £45 million per kilogram, surpassing rocket launch costs.
To ensure the safe return of this valuable cargo to Earth, the company devised a lightweight heat shield named Pridwen, after King Arthur’s shield, which unfolds like an umbrella during re-entry to slow down the satellite for a gentle splashdown in the ocean, facilitating recovery.
ForgeStar-1 stands as a trailblazer.
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The UK’s Satellite Applications Catapult, a supporter of space start-ups, suggests that everything from stronger metal alloys to potent cancer medications could potentially be manufactured in space in the future.
Nafeesa Dajda, head of missions at the Catapult, emphasized the UK’s leading role.
“Satellite technology enables global communication from virtually any location on Earth,” she stated.
“The unique microgravity environment in space presents opportunities for unprecedented advancements that are unattainable on Earth.
“The potential impact for the UK is enormous.
“We project that the opportunity is worth approximately £20 billion to the UK economy over the next decade.”
Space Forge co-founder, Joshua Western, believes materials produced in space can significantly reduce energy consumption on Earth
The team at Space Forge HQ eagerly anticipates the departure of their satellite to the US after years of development efforts. It’s a narrative reminiscent of Silicon Valley.
“It demonstrates what two individuals, who began in a garage on the outskirts of the city, could achieve when they decided to pursue a vision one night at the pub,” remarked Joshua.
“There is currently a positive outlook on technology (in the UK) that we didn’t always have.
“There is renewed momentum in the industrial sector, especially in engineering, despite the current challenges.”