Nov.13, 2014
3D Printing in space is possible. NASA is currently working on "printable spacecraft" and using robots to assemble equipment from 3D printed parts in space, and has already sent the first 3D printer to the International Space Station. Meanwhile Europe has also launches its space 3D Printing project.
Europe's very first 3D printer in space is scheduled for installation aboard the ISS next year, announced European Space Agency today.
Designed and built in Italy, it will be put to the test as part as ESA astronaut Samantha Cristoforetti's Futura mission, and is set to reach orbit in the first half of next year. Samantha herself will be launched on her six-month Station assignment on 23 November.
ESA astronaut Samantha Cristoforetti
This 3D printer, called POP3D (Portable On-Board Printer), is a cube with 25 cm sides and prints with biodegradable and harmless plastic using a heat-based process.
"The POP3D Portable On-Board Printer is a small 3D printer that requires very limited power and crew involvement to operate," explained Luca Enrietti of Altran, prime contractor for the compact printer.
The project involved Altran Italia (prime Contractor and responsible for the development of the printing equipment), Thales Alenia Space (supporting on ISS integration aspects) and IIT (supporting on Characterisation and post-flight analyses).
"Part of the challenge of designing a 3D printer for the Station was to ensure its operation does not affect the crew environment," added Giorgio Musso of Thales Alenia Space Italy, principal investigator for the project.
Funded by Italy's ASI space agency, POP3D should take about half an hour to produce a single plastic part, which will eventually be returned to Earth for detailed testing, including comparison with an otherwise identical part printed on the ground.
ESA's goal is to increase the technological maturity of the additive manufacturing process for extrusion of thermoplastic polymers in microgravity conditions and in manned space environment. ESA has so far tested this manufacturing process on parabolic flights, for a maximum duration of 20-30 seconds. POP3D is expected to be able to print uninterruptedly for about 30 minutes. The manufactured object will be sent to the ground for a comparative analysis with an analogous object printed in 1-G conditions, so as to analyse the diversity (if it exists) between the two.
3D-printed prototype version of the support structure for ESA's Sentinel-1's upper S-band antenna, produced by RUAG Space Switzerland, with Altair and EOS. Produced in metal using selective laser melting, the redesigned part has a mass of 0.94 kg compared to the original part's mass of 1.4 kg, and also boasts improved stability. It was designed using 'topology optimisation', where software decides where material needs to go in order to best meet the part's function, constrained by its stress load and interface points with the rest of the satellite. Credit: ESA
The project was presented during a workshop on 3D printing for space held at ESA's technical centre in Noordwijk, the Netherlands. More than 350 experts from across Europe came together to discuss the potential of 3D printing for space, both in orbit and in ground manufacturing.
The results of the project are expected to bring significant benefits to the industry. "There is big potential all along the value chain, to save cost and mass," noted Reinhard Schlitt, heading OHB's Engineering Services.
"But right now the way parts are being produced in various different ways. As a satellite manufacturer, we need common standards in place so we can compare competing supplier parts on a like-for-like basis.
"Europe does have a lead in this technology – the latest laser machines are coming from here for export to the US and China – so we should build on that."
One-piece 3D-printed satellite bracket for a satellite, designed by Czech company LKE, and manufactured by Brno University of Technology. Produced through selective laser melting, this single-piece metal latticed part has reduced mass compared to its standard counterpart. Its mass is only 164 grams, compared to 222 grams for its traditionally-produced counterpart. Credit: ESA
Using 3D printing technology reduce volumes of cargo on board since functional parts could be produced directly in situ according to the actual needs. In addition printing objects directly on the ISS would avoid having to design parts on the basis of high mechanical stresses they are subject to during the launch phase.
Steffen Beyer, Head of Materials and Process Technology at Airbus Defence and Space added: "it is very promising for reducing costs particularly for complex structures and reducing lead time significantly. In the case of a complex injector of a rocket engine, we are able to take the total number of parts needed down from around 250 down to one or two; that represents a revolution in design and manufacturing."
Posted in 3D Printing Applications
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