NSF Selected Two Physics Projects for ISS Microgravity Study
New experiments aim to refine metal manufacturing and thermal cooling models by isolating surface tension effects in space.
Updated on Sept. 28, 2026 in Physics
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The U.S. National Science Foundation and the ISS National Laboratory have selected two new research projects to be conducted in microgravity. These studies will examine metal powder melting dynamics and two-phase flow boiling to address critical manufacturing and engineering challenges.
Why it matters
On Earth, gravity-induced buoyancy obscures the role of surface tension, making it difficult to create precise predictive models for industrial processes. Research in microgravity provides the conditions necessary to isolate these forces, potentially reducing defects in additive manufacturing and increasing the efficiency of thermal cooling systems.
The partnership has now supported nearly 100 projects on the ISS, resulting in more than 350 peer-reviewed publications. The new experiments specifically seek to quantify data currently masked by gravity, building on a foundation of nearly 100 prior investigations.
The players
National Science Foundation
A U.S. government agency that supports fundamental research and education in all non-medical fields of science and engineering.
ISS National Laboratory
An organization responsible for managing the U.S. portion of the International Space Station as a national resource for research and development.
Patricia Weisensee
A researcher at Washington University in St. Louis leading the study on metal powder melting dynamics.
Chen Li
A researcher at the University of South Carolina leading the project on two-phase flow boiling.
The details
Microgravity removes buoyancy-driven flows, which allows researchers to observe surface tension in isolation. In the melting dynamics study, researchers will analyze how individual metal particles coalesce without gravitational interference. The flow boiling experiment will observe how liquid and bubbles interact within channels, measuring the slip ratio—the relative velocity difference between vapor and liquid phases—to create more accurate thermal management models.
Timeline
The ESA began operating a metal 3D printer on the ISS in mid-2024.
A Chinese team completed a suborbital metal 3D printing test in January 2026.
The NSF and ISS National Lab announced the two new research projects on September 24, 2026.
The Tech Race
This initiative follows the ongoing trajectory of the NSF and ISS National Laboratory research partnership, which has already facilitated nearly 100 space-based studies. The effort represents a U.S. push to standardize microgravity manufacturing data, following recent metal 3D printing tests by European and Chinese research teams.
The findings from these experiments are intended to produce predictive models that engineers will eventually use to design more reliable 3D-printed metal parts and more efficient heat exchangers for electronics. These benefits will materialize in commercial applications only after the models are successfully validated and integrated into industrial design software.
The takeaway
These experiments represent a critical step toward replacing trial-and-error manufacturing with validated physical models. Readers should watch for future publications resulting from these NSF-funded projects to see how microgravity data alters Earth-based additive manufacturing standards.
Further reading
Explore the latest developments in space-based scientific inquiry within the Physics section.
Source note: This article includes information reported by 3D Printing Industry.
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