AIRY is a Danish company specializing in large-scale additive manufacturing for high-performance, lightweight structures. Originally focused on the automotive sector, particularly electric vehicle battery pack structures, AIRY has developed a 6-axis printing system capable of embedding continuous fibers into reinforced thermoplastics. This approach delivers significant weight reductions while maintaining mechanical strength and thermal resilience.

Now, AIRY is adapting this technology for use in space. The development of additive manufacturing for space is driven by the need to reduce the weight and cost of space-bound components, given the high launch costs. Additive manufacturing allows for on-demand production of complex and lightweight parts directly in space, significantly enhancing mission sustainability.

By collaborating with ESA, AIRY is adjusting their technology so it can handle the harsh conditions of space, like big temperature changes, radiation, and vacuum. This collaboration is helping them improve how their system performs, not just in orbit, but also in tough environments here on Earth.

Using 3D printing materials for satellite components

AIRY’s technology makes it possible to produce strong, lightweight parts faster and more efficiently than traditional methods. For the space industry, this means satellite components that are lighter to launch, easier to customize, and cheaper to produce. By printing with continuous fiber-reinforced thermoplastics, AIRY helps reduce the number of parts in a structure, cutting down on weight, complexity, and assembly time.

Because the same technology was originally developed for electric vehicles, it’s already designed for tough conditions, like heat and vibration. Bringing that experience into space helps reduce risk and shortens development time. As a result, companies working with AIRY can move faster from idea to tested, flight-ready hardware.

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“ESA Technology Broker has been instrumental in launching AIRY into Denmark’s—and Europe’s—space ecosystem. Their guidance not only opened doors across the industry but also illuminated the deep-tech opportunities within ESA’s programmes. We are very grateful for their continuous support.” — Gustau Lundegaard Lange, CEO & Founder of AIRY

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AIRY shows how advanced industrial manufacturing can be adapted for space quickly, effectively, and with impact. Their work proves that technologies built for the road can go to orbit, and that space can help companies push their products to the next level.

With support from ESA BIC and the ESA Technology Broker in Denmark, AIRY is opening new doors in the space sector, turning proven manufacturing expertise into flight-ready solutions. Their journey can inspire other companies to look to space not just as a destination, but as a way to grow stronger here on Earth.