Why pharma firms are going to Earth’s orbit in search of new cancer drugs

The three capsules represent a small but significant step towards what some hope will become a lucrative new industry: manufacturing drugs and other materials in space. Varda launched two capsules on October 1, followed by a third on October 20, achieving a record of three commercial re-entry vehicles simultaneously in orbit.

Inside one capsule, tiny crystals of a potential cancer drug are being grown in the weightlessness of space. The other capsules are testing heat protection materials and navigation systems for when they plunge back through Earth's atmosphere at hypersonic speeds.

Microgravity benefits

The primary advantage of space manufacturing is microgravity, which allows crystals to grow more ordered than on Earth. Gravity causes particles suspended in liquids to settle and creates currents that interfere with crystal growth.

For pharmaceutical companies, this could open new ways of formulating medicines, as crystal size, shape and arrangement affect how easily drugs dissolve, their stability, and administration methods. Some drugs requiring intravenous infusions could potentially be reformulated into injections.

Beyond pharmaceuticals

Other materials could benefit from space manufacturing. Semiconductors used in smartphones and electric vehicles might be produced with fewer defects in microgravity and vacuum conditions. Graphene production could also improve, as current Earth-based methods result in many crystal defects.

Companies like UK-based Space Forge are exploring hybrid approaches, returning semiconductor crystals as templates for Earth-based production. Its ForgeStar-1 spacecraft has demonstrated needed processes but hasn't yet produced finished materials.

Commercial challenges

While scientists have experimented with microgravity manufacturing for decades, primarily on the International Space Station (ISS) scheduled for retirement around 2030, commercial viability remains uncertain. Varda's autonomous factories aim to overcome limitations of human-tended laboratories.

Varda plans seven more missions in 2027 and ten in 2028, emphasizing the need for frequent experimentation in drug development. However, significant challenges remain, including demonstrating consistent results and justifying costs against Earth-based alternatives.

Regulators must also adapt to space-manufactured products, with the UK's MHRA expected to publish guidelines later this year. "It's not going to be commercially viable for every application," Christian noted, "We have to identify those high-value use cases where it makes sense to do the work in microgravity."