SpaceX, NASA, ESA, Relativity Space, Blue Origin…what do these all have in common? Why they are all using additive manufacturing in the use of space exploration. And while you may notice that that that list includes many examples from Europe and the United States, other companies from around the world are also joining the 3D printing space race. Take for example Interstellar technologies. The Japanese startup made news earlier this year due to the announcement of significant funding from the Japanese government and Toyota as Japan amps up its efforts in its space programs. To learn more about Interstellar as well as its future projects, we sat down with Satoshi Nakayama.
3DN: Could you introduce yourself and your connection to 3D printing?
Satoshi Nakayama
My name is Satoshi Nakayama, I am a Director of the Board & VP of Launch Vehicle at Interstellar Technologies Inc. Before joining Interstellar, I had spent 12 years at Mitsubishi Precision Company, where I served as Project Manager for the development of navigation sensors for rockets operated by the Japanese Government, gaining frontline experience in Japan’s space industry. I joined Interstellar in 2021, where I have worked in avionics development, reliability design, and quality assurance. I was appointed VP of Launch Vehicle in May last year.
During my time working with government-operated rockets, I felt that the traditional, risk-averse nature of Japan’s space industry made it difficult to embrace new technologies and innovations. Working at Interstellar is a different experience since we dare to break away from convention and take on bold new challenges. I believe Interstellar’s mission is to drive transformation in Japan’s space industry.
ZERO, our orbital vehicle, is packed with new suppliers, innovative components, and groundbreaking technologies. By successfully launching ZERO, we aim to turn these challenges into proven achievements, contributing to the expansion of not only Japan’s but also Asia’s space industry and the strengthening of its supply chain.
3DN: What is Interstellar Technologies’ mission? How did the company come about?
Interstellar Technologies is a Japanese startup born in 2013 dedicated to building affordable and accessible space infrastructure, striving to create a future where space is within everyone’s reach. We have launched seven times, with three successful suborbital launches, making Interstellar the first private Japanese company to reach space. Our team has grown to over 200 employees located in four different offices around Japan.
We are currently developing the orbital launch rocket ZERO and the Our Stars satellite services, aiming to establish Japan’s first vertically integrated rocket and communications satellite business.
3DN: Could you tell us about how you use additive manufacturing to make rockets? What are the benefits of using additive manufacturing for space applications?
In rocket manufacturing, additive manufacturing is leveraged to enhance design flexibility and improve production efficiency. One of its key advantages is the ability to integrate complex components such as engine parts and turbopumps into a single structure. This leads to fewer components, reduced weight, increased strength, and enhanced reliability, contributing to the overall optimization of the rocket.
For example, ZERO utilizes a turbopump that rotates an impeller to deliver fuel to the engine. This turbopump is powered by a Gas Generator (GG), a small rocket engine that burns liquid methane and liquid oxygen. The combustion gas is directed onto turbine blades, which drive the turbopump.
The turbopump used in ZERO
The GG operates at around 400°C, a relatively low temperature, and features a spherical combustion chamber. To reduce production costs, the chamber is cast using a 3D-printed mold filled with Inconel, a heat-resistant alloy.
Additionally, the injector, which delivers fuel into the combustion chamber, is 3D printed from stainless steel. Since injectors require precise internal flow channels to create complex spray patterns, additive manufacturing enables intricate geometries with fewer components and machining steps.
Furthermore, the turbopump turbine manifold that directs GG combustion gases to the turbine is 3D-printed from Inconel and integrated with the turbopump structure. This approach allows for a lightweight yet streamlined design, while also incorporating highly efficient internal flow channels for optimal gas distribution to the turbine.
By adopting 3D printing, parts that once required months to manufacture using traditional precision casting and machining can now be produced more efficiently. This accelerates development at Interstellar, enabling faster innovation in rocket technology.
3DN: You have raised quite a lot of money from companies like Toyota as well as the Japanese government. How will you be using this to advance Japan’s presence in Space? How will AM play a role?
The demand for small satellite launches has been growing exponentially and some countries have been following the pace better than others. For example, the United States and China conducted 158 and 68 launches respectively in 2024, while Japan’s launch frequency remained limited to only 7 per year.
To address this, the Japanese government has set a goal to secure around 30 domestic launches per year by the early 2030s to meet diverse domestic and international launch demands. In fact, Interstellar was selected for the SBIR, a program created by the Japanese government to boost the development of space technology, from which we have secured up to ¥8 billion ($53.5 million).
The strategic capital and business alliance with Woven by Toyota, Inc., a Toyota Group company focuses on incorporating Toyota’s expertise in key areas such as cost optimization, lead time shortening, and the establishment of a mass production system for launch vehicles. Together, we want to strengthen the supply chain and corporate governance, with the goal of advancing rocket mass production to offer internationally competitive launch services that expand Asia’s access to space.
Interstellar’s main office in Taiki
As for AM, currently, in rocket development worldwide, large components such as propellant tanks and combustion chambers are increasingly being produced using 3D printing.
Additive manufacturing offers significant advantages, including fewer components, reduced weight, enhanced strength, and improved reliability. At Interstellar, we are actively working on expanding the application of 3D printing by developing new manufacturing processes and materials.
By advancing these technologies, we aim to enhance ZERO’s market competitiveness while also contributing to the growth of Japan’s space industry and the strengthening of its supply chain. Moving forward, we will continue to explore new possibilities in design and manufacturing to push the boundaries of space technology. You can find out more about Interstellar at our website HERE.
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