Three washing machine-sized capsules are currently orbiting Earth at an altitude of roughly 300 miles, conducting experiments that could reshape the pharmaceutical industry. One of these vessels, operated by California-based Varda Space Industries, is growing tiny crystals of a potential cancer drug in the weightlessness of space. The other two capsules are testing heat protection materials and navigation systems for their return journey through the atmosphere.
This mission marks a significant milestone for the company, which launched two capsules on October 1 and the third on October 20. With three spacecraft in orbit simultaneously, Varda is moving closer to its goal of operating a fleet of orbiting pharmaceutical factories. Will Bruey, the chief executive of Varda, stated that the company is the first to launch multiple commercial re-entry vehicles at the same time. He noted that as launch frequency increases, the concept of manufacturing products in space is becoming a reality rather than a distant fantasy.
Microgravity and Crystal Growth
The primary advantage of conducting these experiments in space is microgravity. On Earth, gravity causes particles in liquids to settle and creates density-driven currents. These forces can interfere with the growth of crystals, leading to irregular structures. Dr. Meganne Christian, mission manager for in-space manufacturing at the UK-based Satellite Applications Catapult, explained that removing these effects allows crystals to grow in a more ordered manner.
For pharmaceutical companies, the size, shape, and arrangement of drug crystals are critical. These factors influence how easily a medicine dissolves, its stability, and how it can be administered. In some cases, reformulating drugs using space-grown crystals could allow medications that currently require intravenous infusions to be converted into more convenient injections. The technology also holds promise for producing purer semiconductors and materials like graphene, which often suffer from defects when manufactured on Earth.
Autonomous Factories and Future Missions
While scientists have experimented with microgravity manufacturing for decades aboard the International Space Station, that facility is scheduled for retirement around 2030 and was not designed for industrial-scale production. Dr. Ryan Reeves, deputy chief scientist for the ISS National Laboratory, noted that the station served primarily as a test kitchen for scientific ideas. Commercial space stations are being developed to replace it, but Varda is pursuing a different approach with its autonomous free-flyers.
These free-flyers hitch rides into orbit on SpaceX rockets and carry miniature laboratories that operate without astronauts. Dr. Christian pointed out that humans introduce vibrations and contamination, which can disrupt sensitive manufacturing processes. Once experiments are complete, a capsule separates from the spacecraft, plunges through the atmosphere and parachutes to an uninhabited region of Earth. Varda has already returned several capsules from orbit and plans to launch seven more missions in 2027, followed by ten in 2028.
Michael Reilly, Varda’s chief strategy officer, emphasized that frequent experimentation is essential for modern drug development. Waiting years between experiments does not align with the pace of the industry. Other companies are also entering this space. Cardiff-based Space Forge is developing a hybrid approach to grow semiconductor crystals in orbit, with co-founder Andrew Bacon hoping to demonstrate the full manufacturing and return process before 2030.
Despite the optimism, challenges remain. Dr. Christian warned that space manufacturing will not be commercially viable for every application. The industry must identify high-value use cases where the benefits of microgravity justify the expense. Regulators are also adapting to these new methods. The UK’s Medicines and Healthcare products Regulatory Agency is expected to publish a plan later this year clarifying how existing regulations apply to drugs manufactured in orbit. For now, the focus is on demonstrating consistent, repeatable results to prove the technology’s reliability.
Source: The Guardian
