South Korean researchers have achieved a major milestone in space manufacturing by successfully testing the world’s first 3D-printed titanium Space fuel tank to pass extreme cryogenic pressure conditions, marking a breakthrough that could transform how spacecraft components are produced.
The 640mm diameter tank, manufactured using Ti64 titanium alloy through Directed Energy Deposition (DED) 3D printing, withstood pressures of 330 bar while cooled to -196°C with liquid nitrogen during testing at the Korea Aerospace Research Institute (KARI). The pressure test exposed the tank to forces 165 times greater than standard tire pressure, demonstrating its reliability under the extreme conditions of space missions.
Addressing Supply Chain Vulnerabilities
The achievement represents a strategic shift for South Korea’s space industry, which has historically relied on imported titanium components, primarily from Ukraine. Recent geopolitical tensions have highlighted vulnerabilities in this supply chain, making domestic production capabilities increasingly critical.
According to Popular Science, the traditional forging process for these components can take six months to a year, with long lead times that slow vehicle development schedules. In contrast, the 3D printing process took just three days to print the tank hemispheres, with the entire manufacturing cycle completed within weeks.
The project was a collaboration between the Korea Institute of Industrial Technology (KITECH), KARI, KP Aviation Industries, AM Solutions, and Hanyang University.
Overcoming Industry Skepticism
Initial resistance to using additive manufacturing for safety-critical space applications stemmed from concerns about potential micro-defects that could prove catastrophic for high-pressure vessels. The technology had previously been limited to creating basic shapes rather than components requiring certification for the extreme conditions of actual launches.
“It was a high-stakes test where failure meant the prototype could explode like a bomb, so initially, we faced significant reluctance from others to even make the attempt,” explained Dr. Lee Hyub, principal researcher at KITECH. The successful cryogenic pressure test at KARI, conducted within a safety facility enclosed by concrete barriers, demonstrated that 3D-printed components could meet the high reliability standards demanded by space environments, effectively silencing industry doubts about the technology’s viability for mission-critical applications.
Implications for ‘New Space’ Era
The breakthrough addresses growing demand for customized parts in the private-led “New Space” industry. Unlike the era of standardized components, today’s space companies require tanks in various shapes and sizes – from 110L alternatives to standard 130L tanks, or different geometries like cylinders.
This development follows a trend of 3D printing proving its worth in aerospace applications. Companies like Lockheed Martin have previously developed 46-inch diameter 3D-printed titanium satellite fuel tanks, reducing production timelines from two years to three months. Meanwhile, Rocket Lab incorporates 3D printing in 95% of its Rutherford engine components.
The Korean team now plans additional testing to prepare the technology for commercial deployment, potentially revolutionizing how pressure vessels and other critical space components are manufactured for satellites, launch vehicles, and crewed spacecraft.
How quickly can South Korea scale this technology to compete with established space manufacturers
While South Korea’s development of a 3D-printed titanium fuel tank is a significant technological leap, scaling this capability to compete with established international space manufacturers involves navigating substantial challenges related to launch frequency, public-private partnerships, and overall market competitiveness.
Path to Commercialization
There is no definitive public timeline for scaling the production of these 3D-printed tanks, but the immediate focus is on preparing the technology for the commercial market. The research consortium, which includes the Korea Institute of Industrial Technology (KITECH) and the Korea Aerospace Research Institute (KARI), plans to conduct more tests and work with private space companies to bring the technology to market.
This effort is part of a broader national strategy to become a top-five global space power by 2045, with ambitious goals that include a lunar landing by 2032 and a Mars landing by 2045. To support these goals, the government intends to double its investment in space development by 2027 and increase the nation’s share of the global space market from 1% in 2021 to 10% by 2045.
Hurdles to Global Competition
Despite its technological prowess in areas like 3D printing, South Korea faces several hurdles as it aims to scale its space manufacturing capabilities:
- Latecomer to the Market As a relative latecomer to the space industry compared to regional peers like Japan, China, and India, South Korea is still building its reputation and capabilities. As of 2025, the country has not yet launched a foreign payload, a key step in entering the commercial launch market.
- Slow Launch Cadence A significant challenge is the slow pace of launches. The Nuri (KSLV-II) rocket’s fourth launch is scheduled for November 2025, a 2.5-year gap since its third launch in 2023. Such extended intervals risk eroding hard-won technical expertise and losing momentum in the fast-paced global market.
- Public-Private Friction The transition to a private-led space ecosystem has encountered obstacles. The development of the next-generation KSLV-III rocket has faced delays due to an intellectual property (IP) rights dispute between the government-funded KARI and Hanwha Aerospace, the private contractor leading the project.
- Economic Competitiveness To effectively compete, South Korea must lower launch costs. This will likely require innovation in reusable rocket technology to match the economies of scale achieved by global leaders like SpaceX. Broader supply chain issues also persist, as seen in delays for the private HANBIT-Nano rocket, which has pushed companies to diversify suppliers for critical components.
The success of South Korea’s push into the global space market will largely depend on the ability of its new Korea Aerospace Administration (KASA), founded in 2024, to effectively manage the transition to a commercially-driven industry. Leveraging the nation’s existing industrial strengths in semiconductors, AI, and advanced manufacturing will be critical to overcoming its latecomer status and establishing a competitive position.
