Space-based production: companies target cancer drug manufacturing in orbit

California-based Varda Space Industries launched two capsules on October 1st, followed by a third on October 20th. This marks the first time the company has simultaneously maintained three spacecraft in orbit, bringing them closer to their goal of operating a fleet of orbiting manufacturing facilities.

“We’re the first company in human history to launch multiple commercial re-entry vehicles simultaneously, and as the frequency of launches increases, the once ‘crazy future’ of manufacturing products in space is becoming more and more certain,” stated Will Bruey, Varda’s chief executive.

The appeal of space-based manufacturing stems largely from the absence of gravity. On Earth, gravity causes particles in liquids to settle and creates currents that can disrupt crystal growth. Removing these effects allows for the creation of more ordered and uniform crystals.

This capability could revolutionize pharmaceutical formulation, potentially enabling drugs currently administered via intravenous infusion to be reformulated into injections. The size, shape, and arrangement of drug crystals significantly impact drug dissolution, stability, and administration methods.

Beyond pharmaceuticals, other materials like semiconductors, vital for smartphones and electric vehicles, could also benefit from space-based production. Microgravity and the lack of air can facilitate the creation of purer crystals with fewer defects.

Scientists have explored microgravity manufacturing for decades, primarily on the International Space Station (ISS). However, the ISS, slated for retirement around 2030, was not initially designed for manufacturing. Several companies are developing commercial space stations and specialized laboratories to replace the ISS.

For large-scale production, human involvement is deemed problematic due to potential contamination and vibrations. Varda’s autonomous factories, known as free-flyers, address this by carrying miniature laboratories into orbit via SpaceX rockets. After experimentation, a capsule separates, re-enters the atmosphere, and lands safely.

Varda has already successfully returned capsules from orbit and plans to launch seven more missions in 2027 and ten in 2028. Frequent experimentation is crucial for drug development, as lengthy delays hinder progress.

While Varda focuses on pharmaceuticals, other companies are pursuing similar approaches. Cardiff-based Space Forge is exploring a hybrid method, using semiconductor crystals grown in space as templates for larger-scale production on Earth.

Andrew Bacon, Space Forge’s co-founder and chief technology officer, believes space manufacturing is reaching a pivotal moment. “Since we started in 2018, nobody was talking about it. Now a lot of companies [are] talking about it,” he said. “People are starting to take this market very seriously. It does feel like we’re at the start of a new Industrial Revolution.”

Lower launch costs and increased commercial rocket flights have fueled this optimism. However, demonstrating the economic viability of space manufacturing remains a challenge. Regulators, including the UK’s Medicines and Healthcare products Regulatory Agency (MHRA), are preparing to adapt existing regulations for space-manufactured products, with a plan expected later this year. Consistent, reliable results are paramount for commercial success.