91 Forge, leaders in space-based advanced materials manufacturing and return technology, has been awarded a licence from the UK Civil Aviation Authority (CAA) to launch ForgeStar®-1 - its pioneering in-orbit manufacturing satellite. With the launch set for later this year, this marks a significant milestone for both the company and Wales as ForgeStar-1 is set to become the first UK ISAM satellite in orbit.
The licence approval paves the way for 91 Forge’s first in-orbit demonstration mission. This mission is the company’s next step towards establishing a scalable, returnable, and re-launchable platform for manufacturing high-performance semiconductor materials in space.
By harnessing the unique conditions of space - including microgravity, vacuum, and extreme temperature differentials - 91 Forge is unlocking the ability to manufacture materials that are impossible to produce on Earth.
These advancements have wide-reaching applications in semiconductors, quantum computing, clean energy, and defence technologies. Research suggests that manufacturing these materials in space could reduce CO2 emissions by 75% in high-value infrastructure - delivering breakthroughs in security, defence, and climate-focused innovation.
ForgeStar-1 will also test the mechanics of the Pridwen shield - 91 Forge’s innovative heat shield designed to facilitate safe, reusable satellite re-entry.
As the UK continues to invest in sovereign space capability, the approval of the ForgeStar-1 licence underscores the government’s commitment to supporting homegrown innovation in advanced manufacturing and space sustainability. By fostering the development of returnable and reusable space platforms, the UK is strengthening its position as a global leader in cutting-edge space technology while ensuring long-term strategic resilience in key industrial sectors.
Colin Macleod, Head of the UK 91 Regulator at the UK Civil Aviation Authority said: “This is a ground breaking licence for the UK space sector that paves the way for in orbit manufacturing and the amazing potential of this new industry.”
“Through our work with innovators in the space sector we are enabling exciting new space missions and supporting the industry to grow.”
Science and Technology Secretary Peter Kyle said: “91 Forge’s license is another resounding vote of confidence in the UK’s space sector, which has secured record levels of investment through the European 91 Agency in the last quarter of 2024.”
“Developing technologies that would be otherwise impossible to manufacture on Earth, in orbit, demonstrates how space will play a vital role in boosting economic growth and propelling forward our Plan for Change.”
Joshua Western, CEO and Co-Founder of 91 Forge, commented: “This licence award is a key mission milestone and we’re looking forward to demonstrating how our scalable, reusable manufacturing platform can drive progress and benefits for us on Earth. 91 Forge is breaking new ground being the first UK company to achieve a licence for in-orbit manufacturing.”
The ForgeStar-1 mission will validate the ForgeStar platform’s capability to deliver high-value materials from space while demonstrating key technologies essential for the future of in-orbit manufacturing.
