SpaceX planning to use Starship for manufacturing in space

It appears the enthusiastic investment response last week to the potential of using Varda’s re-turnable capsule for manufacturing in space (especially of pharmceuticals) has caught SpaceX’s interest. According to a news report yesterday, SpaceX has now begun developing a program to use Starship for the same purpose, delivering the raw materials in orbit for short or long periods while these products are produced automatically and then returning them for sale on Earth.

Under the plan, internally called Starfall, SpaceX’s Starship rocket would bring products such as pharmaceutical components to space in small, uncrewed capsules, said one of the people, who spoke on condition of anonymity because the matter is confidential.

Starship would then deploy the capsules, which would spend time in orbit before reentering the atmosphere, where they could be recovered back on Earth, the person added.

This description by this anonymous source seems inaccurate however. Why even consider using these small separate capsules when the entire operation can be put inside Starship, which can then bring everything home when ready? Moreover, Starship’s ability to put a lot of mass in a large space up into orbit gives it an great advantage over the smaller capsules being developed by companies like Varda.

Either way, the advantages of weightlessness for producing products for profit are finally being realized, after decades of blockage by government intransigence. Since the Challenger accident in 1986 and Reagan’s order that the shuttle would no longer not be used for commercial purposes, NASA has forbidden production on its spacecraft and ISS of any products for sale afterward.

Now that the cost of launch has dropped significantly (Thank you Elon Musk!), many investors and companies are seeing great potential for manufacturing in space. And those profits will help feed a private space industry, making the government agency of NASA even more irrelevant.

Varda quickly raises $90 million after completing its first orbital manufacturing mission

As expect, Varda announced yesterday that it raised $90 million in investment capital following the publication of the results of its first orbital manufacturing mission, where its returnable capsule was used to produce test pharmaceuticals in space that cannot be made on Earth.

Varda announced April 5 it raised a Series B round led by venture firm Caffeinated Capital, with participation from Lux Capital, General Catalyst, Founders Fund and Khosla Ventures. The company has raised $145 million to date. The funding round comes on the heels of the successful conclusion of its first demonstration mission, W-1, on Feb. 21 when the company’s capsule landed at the Utah Test and Training Range. The capsule had been part of a spacecraft launched in June 2023 to test the ability to produce pharmaceuticals in microgravity.

The new funding will allow Varda to scale up production of spacecraft that take advantage of microgravity to produce pharmaceuticals that are not possible or cost-effective to make on the ground.

The company already has a second returnable capsule scheduled for launch this summer on a Rocket Lab Electron rocket.

Varda releases results of its in-orbit test for producing pharmaceuticals in weightlessness

On March 20, 2024 Varda released the results from its seven-month-long flight of its unmanned capsule, claiming that the technology worked to produce pharmaceuticals in weightlessness that will be better at treating some difficult illnesses such as HIV.

From the abstract of the preprint paper [pdf]:

Despite notable progress in realizing the benefits of microgravity, the physical stability of therapeutics processed in space has not been sufficiently investigated. Environmental factors including vibration, acceleration, radiation, and temperature, if not addressed could impact the feasibility of in-space drug processing. The presented work demonstrates the successful recovery of the metastable Form III of ritonavir generated in orbit. The test samples and passive controls containing each of the anhydrous forms of ritonavir; Form I, Form II, Form III, and amorphous exhibit excellent stability. By providing a detailed experimental dataset centered on survivability, we pave the way for the future of in-space processing of medicines that enable the development of novel drug products on Earth and benefit long-duration human exploration initiatives.

More research is likely required, but I suspect Varda will be able to raise investment capital from this success, since there is a lot of money to be made from pharmaceuticals that can only be produced in weightlessness.

Rocket Lab completes Photon transport spacecraft for Varda’s private returnable space capsule

The private rocket company Rocket Lab has now completed construction on the Photon transport spacecraft that the private company Varda has purchased to maneuver and then de-orbit its private returnable space capsule in which it plans to manufacture pharmaceuticals while in orbit and then return to Earth for sale.

Rocket Lab made the spacecraft at its Long Beach manufacturing site to provide power, communications, propulsion and attitude control to a capsule that will produce pharmaceutical products in microgravity. In addition to providing support during the in-space phase of Varda’s mission, the Photon will put Varda’s capsule carrying finished pharmaceuticals on a return trajectory to Earth.

This is the first of four Photon spacecraft that Varda has purchased from Rocket Lab. Varda appears to be attempting to continue the pharmaceutical work that McDonnell-Douglas did on the space shuttle, and was on the verge of flying a full-scale production mission for profit, when the Challenger accident occurred in 1986 and ended all further commercial work on the shuttle.