May 11, 2014

Today, human spaceflight missions are still dependent on Earth for the resupply of necessary equipment and accessories. When a part is broken, astronauts have to wait on the next cargo resupply mission to bring them a replacement.

To prepare for a future where parts can be built on-demand in space, in 2013 NASA announced ambitious plans to launch equipment for the first 3D microgravity printing experiment to the International Space Station. Partnered with Made in Space Inc. of Mountain View, California, Nasa will launch the first 3D printer to space in 2014. If successful, the 3D Printing in Zero G Experiment will be the first device to manufacture parts in space.

In-orbit ABS plastic recycling system for 3D printer filament

To truly "develop a self-sustaining, closed-loop on-orbit manufacturing process that will result in less mass to launch and increased on demand capability in space", NASA has decided to awards for two new projects on 3D printing. Each year, NASA invests approximately $130 million in technology development through the Small Business Innovation Research (SBIR) and the Small Business Technology Transfer (STTR) Programs. This year they have selected Made in Space again for project R3DO, 'a plastic recycling system for creating 3D printer feedstock on-orbit' under the SBIR award. The award is around $125,000 for six months.

With the funding, Made in Space will further develop their unique recycling system, R3DO, for transforming ABS plastic parts on ISS into 3D printer filament. R3DO's patent-pending technologies enables extrusion process in microgravity, and it also includes unique innovations such as "filament use in microgravity, the low-power heating system, microgravity stabilization, material control, breaker plate migration, material-filter interactions, cooling characteristics, and safety mechanisms."

Made In Space has developed and tested four prototype iterations of R3DO in the lab. The goal is to build a recycler that is capable of decomposing an ABS plastic part (maximum size of 6 cm x 12 cm x 6 cm) and transforming them into 1.75mm (±0.1mm) diameter wire spools, pellets, or other forms that can be fed into an extruder, all in microgravity. Made In Space will have to work on gravity-independent filament spooling, environmental containment for Foreign Object Debris (FOD) and material off-gassing, and methods to avoid bulging of feedstock as the filament is created.

In 2015, Made In Space is going to manufacture hardware on demand in space.

Hybrid plastic/metal 3D printing in orbit

Under the STTR award, NASA is also working with Made in Space and the University of Central Florida in Orlando to develop MicroCast, a novel method for fabricating electronics containing both metals and polymers that can be adapted to produce micro-well sensors. This $125,000 award is also for six months.

The process revolves around creating a polymeric part through additive manufacturing, leaving voids and trace capillaries. Once the polymer structures are completed, molten metal is injected into these trace capillaries, which create a path to the voids in the printed parts. Capillary forces cause the liquid metal to wick into the capillary channels, filling the voids before solidifying. Unlike competing metal additive manufacturing techniques, the parts can be created with 100% dense metal elements that have low surface roughness and are completely compatible with the surrounding polymer.

NASA plans to integrate Made In Space's 3D printer and casting systems into the ISS in the near future. The in-space fabrication of micro-electronics could provide numerous unique applications for NASA.

 

Posted in 3D Printing Technology

Maybe you also like:


   




Leave a comment:

Your Name:

 


Subscribe us to

3ders.org Feeds 3ders.org twitter 3ders.org facebook   

About 3Ders.org

3Ders.org provides the latest news about 3D printing technology and 3D printers. We are now seven years old and have around 1.5 million unique visitors per month.

News Archive