The Space Show Presents George Tyson, Tuesday, 7-28-26.
The Space Show featured George Tyson, CEO of Orbital Construction Pioneers, discussing his company’s concept for building large orbital structures using additive manufacturing with bio-based materials, primarily plant-based epoxies and fillers like hemp. He detailed the “First Step” project, which aims to create a rotating disk-shaped space station called Station 520, with initial construction relying on materials grown and processed in orbit. Tyson explained the current research phase, focusing on material testing and 3D printing technology, and mentioned partnerships such as with Exo Scientific for life support systems. The conversation covered technical aspects like structural design, launch costs, regulatory considerations, and the long-term goal of establishing an Earth-independent space economy. Tyson also introduced the Interplanetary Regen Network (IRN), a proposed consortium to collaborate on space development. The discussion included questions from co-host John Jossy and other participants about feasibility, timelines, and potential applications of the technology.
George discussed his experience from 2005 when he participated in a space tourism assessment, finding that while there was public interest, it wasn’t sufficient to support expensive space tourism flights. He advised companies like XCOR to focus on flying scientific experiments multiple times before sending them to the ISS, which XCOR had planned to implement before other issues arose. The discussion also covered current space tourism status, with John noting that Virgin is not doing well and Blue Origin has shifted focus, while SpaceX is doing some tourism but not much, and George expressing interest in stratosphere balloon rides as a more viable luxury tourism option.
The group discussed their experiences with early television technology, particularly watching the Apollo landings on black and white TVs. They shared personal anecdotes about watching the moon landings in various locations, from hotel rooms to living rooms, and compared these experiences to modern large-screen TVs and electronic devices. The conversation also touched on advancements in electronics, including high-speed oscilloscopes, with Marshall sharing a story about purchasing a $250,000 oscilloscope for work at TI.
George Tyson, CEO of Orbital Construction Pioneers, was our main guest. His large program focused on his flagship “First Step” project, which involves building Station 520 - a 320-meter diameter orbital station that will use additive manufacturing with biological materials grown in orbit to create panels and structures. The station will be constructed using about seven vehicles the size of Starship, with initial framework and plants lifted from Earth, and will serve as a manufacturing hub producing fresh water, oxygen, and food while processing waste products from customers.
George talked about his company’s development of plant-based biopoxy materials for space construction, explaining that they have tested various formulas including hemp for fillers and are working on 3D printing capabilities. The team discussed their plans for a disc-shaped space station (Station 520) with a 3-meter-thick wall structure that would be hollow with different gravity levels, though specific details about density and mass remain undetermined as they are still in research and testing phases. George outlined their approach to becoming Earth-independent through aquaponics and hydroponics systems that would process waste materials from other stations while providing oxygen, water, and food in exchange for technical support and resources.
George explained their 3D printing process using hemp fibers, noting they currently chop fibers to quarter-inch lengths and mix with wood pulp as filler. When asked about launch costs, George indicated they expect costs to eventually reach around $100 per kilogram, similar to what was needed for space manufacturing in 2005, though initial costs will be higher. George confirmed they have experience dealing with regulatory bodies, having previously obtained space flight approval for a training course in 2006-2007, and expressed confidence in working with the FAA to navigate new regulatory challenges for their space manufacturing facility.
George explained that his space development project is still in early stages, with ground testing planned before any FAA approvals will be needed. He described his background in mechanical engineering and NASA experience, which led him to form Black Sky Training and later explore 3D printing applications for space development. The team is researching the possibility of using plants for space construction, inspired by a DARPA proposal about growing structures in space.
Our guest mentioned his recent presentation at ISDC, noting that while time constraints affected the full presentation, there was significant interest and engagement from attendees, leading to opportunities for further discussions. John Jossy introduced George to Daniel Tompkins and his project, Grow Mars, which involves self-replicating greenhouses using local resources for algae production and 3D printing. George expressed interest in collaborating with Tompkins and requested John share his contact information. George also shared that despite a board member’s resignation, the organization is seeking new members to bring fresh perspectives and challenge existing assumptions.
George explained the construction process for building a space station, describing how they would use a metal frame (called Stelimer) to create a structure that could be shipped from Earth, which would then be sheeted with the same material. He clarified that while current stations would use 3D printing within a framework, future stations would print beams and frames directly and confirmed that the 3D printers could operate in vacuum conditions without requiring gravity. The discussion also covered surface texture options for the 3D-printed materials, with George suggesting several methods including spray guns and specialized formulas for smoother finishes.
George also shared plans for Station 520, emphasizing the importance of developing robotics for operations like sheeting and farming to minimize human involvement. He mentioned collaborating with Exo Scientific on a regenerative life support system and expressed interest in connecting with other private space station companies. George also noted that a revised business plan, including a clearer roadmap, would be published soon, potentially for submission to the ISDC business plan competition. John Jossy proposed collaborating on a blog post about space settlement progress, to which George agreed. The discussion concluded with George sharing ideas about large rotating space stations for long-duration missions, including concepts for growing food and raising animals.
Special thanks to our sponsors:
American Institute of Aeronautics and Astronautics, Helix Space in Luxembourg, Celestis Memorial Spaceflights, Astrox Corporation, Dr. Haym Benaroya of Rutgers University, The Space Settlement Progress Blog by John Jossy, The Atlantis Project, and Artless Entertainment
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