3D Printing in Space

What is 3D printing? Making a physical object from a three-dimensional digital model 3D printers use a technique called extrusion additive manufacturing Builds objects layer by layer out of polymers, metals and other raw materials Multiple 3D printing technologies: Selective Laser Sintering (SLS) Fused Deposition Modelling (FDM)

Applications Current applications: Theoretical applications : Eliminate reliance on materials and parts launched from the ground Produce tools and equipment on demand Delicate parts can be manufactured on-orbit Manufacture hard-to-build items more effectively Theoretical applications : Develop self repairing machinery Terraforming The ability to manufacture on demand in space is going to be a paradigm shift for the way development, research and exploration happen in space The technology could help make space exploration cheaper and more efficient, advocates say, by reducing the need to launch all mission components and parts from Earth. Eliminates reliance on materials and parts launched from the ground About 30 percent of the spare parts currently on the space station, can be manufactured using 3D printing technology. Delicate parts could be manufactured on-orbit, avoiding the need to design parts to withstand the stresses of launch. One big advantage of 3D printing is the tech's ability to manufacture hard-to-build items. For example, a 3D-printed titanium lattice ball like the one shown here has a hollow interior with a complex internal geometry. Satellites could self-print new subsystems to provide new capabilities.

Limitations Some challenges for this technology to overcome: Ability to withstand the rigors of launch Compatibility with space station interfaces Understanding the impact of physics in microgravity Compliance with safety and operational constraints Differences with product production in space versus on Earth Overcoming problems of material post-processing New qualification standards Overcoming problems of material post-processing, surface coating and ensuring necessary precision geometries still need solutions. It’s important to note this technology is still in it’s infancy, and although there are some challenges, it’s gaining increasing appeal and will be studied closely in the coming years. Over time it will certainly develop. The first item produced in 2009 was a titanium copy of a stainless steel "woov" (water on-off valve) flown on ESA's Columbus module of the International Space Station as a plumbing component. The woov contained both thick and thin walls, plus a weld. The 3D printed version allowed for removal of the weld, a weak point, and by changing the material reduced the item's mass by 40 percent. An antenna support strut had its mass reduced by 46 percent, while a radio-frequency filter possessing an internal silver coating – normally produced by bolting halves together – had 50 percent of its mass chopped out and its manufacturing time slashed down by several weeks. Its internal geometry grew wavier, as the silver coating required to optimize its radio-frequency performance proves far easier to apply than when dealing with sharp corners, showing another advantage of 3D printing.

Current Projects ‘Made in Space’ printer cleared for testing on International Space Station MSG (August) NASA awarded $125,000 grant to develop a space food making 3D printer Lockheed Martin & RedEye produced test versions of satellite fuel tanks 3D technology will help craft components for the Arkyd line of prospecting spacecraft ESA project to design a lunar base using 3D-printed moon rock The ‘Made in Space’ 3D printer has passed its final set of NASA checks, clearing the way for the device to launch toward the International Space Station in August. Once the machine is installed in the space station's Microgravity Science Glovebox (MSG), it will print out a set of 21 test parts and tools, which will eventually be returned to Earth for analysis. NASA also awarded a $125,000 grant to develop a space food making 3D printer that could be used on long-duration manned missions to deep solar system locations like Mars. Lockheed Martin has partnered with RedEye to produce test versions of satellite fuel tanks Billionaire-backed asteroid-mining company Planetary Resources is teaming up with 3D Systems, whose 3D printing technology will help craft components for the Arkyd line of prospecting spacecraft One ESA project to design a lunar base using 3D-printed moon rock demonstrates this incredible potential.