Manufacturing light-metal components on demand and on site is a major challenge in space. So far, some AM technologies have been considered, but working with loose metal powder or large amounts of solvents are undesirable attributes of some processes. The hybrid approach of gel casting into recyclable polymer molds fabricated using FFF presents a possible alternative for use under terrestrial and reduced gravity conditions, with low equipment requirements and no loose powder. We have investigated the production of Ti-6Al-4V components and developed a metal powder suspension for this purpose. We present sintering results with 0.1 % porosity and impurity values according to the specification, as well as demo parts that we were able to manufacture with this process chain. Filling of the molds under different gravitational conditions is a specific challenge and can be predicted with a numerical simulation to analyze the flow characteristics and check for air entrapment.