Nov.26, 2014

The International Space Station's 3D printer has manufactured the first 3-D printed object in space, paving the way to new age of off-Earth manufacturing.

International Space Station Commander Barry "Butch" Wilmore holds up the first object made in space. Image Credit: NASA

NASA's 3D printer was developed with the startup Made In Space, with the purpose to experiment with possibility of manufacturing crucial replacement parts on the station. The 3D printer uses a process similar to the earthly variety: plastic filament is fed through the machine and extruded one layer at a time to build the part. NASA astronaut Barry "Butch" Wilmore, Expedition 42 commander aboard the International Space Station, installed the Zero­G 3D Printer on Nov. 17 and conducted the first calibration test print. Since then the crew has been printing out plastic test items to verify if the printer was ready for manufacturing operations.

On Nov. 24, ground controllers sent the printer the command to make the first printed part: a faceplate of the extruder's casing.

"This first print is the initial step toward providing an on-demand machine shop capability away from Earth," said NASA's Niki Werkheiser, project manager for the International Space Station 3-D Printer. "The space station is the only laboratory where we can fully test this technology in space."

On Tuesday, November 25, the first part was manufactured by the 3D printer. However the space environment poses challenges: "Part adhesion on the tray was stronger than anticipated, which could mean layer bonding is different in microgravity, a question the team will investigate as future parts are printed." NASA reported. Wilmore installed a new print tray, and the ground team sent a command to fine-tune the printer alignment and printed a new calibration coupon. When Wilmore removes the calibration coupon, the ground team will be able to command the printer to make a second object.

The teams at NASA and Made In Space said they are learning a lot, even from these initial operations. "As we print more parts we'll be able to learn whether some of the effects we are seeing are caused by microgravity or just part of the normal fine-tuning process for printing." said Werkheiser. "When we get the parts back on Earth, we'll be able to do a more detailed analysis to find out how they compare to parts printed on Earth."

The printhead faceplate, is engraved with names of NASA and Made In Space, Inc. As the first objects are printed, NASA and Made In Space engineers are monitoring the manufacturing via downlinked images and videos. The majority of the printing process is controlled from the ground to limit crew time required for operations.

The first objects built in space will be returned to Earth in 2015 for detailed analysis and comparison to identical ground control samples made on the flight printer after final flight testing earlier this year at, NASA's Marshall Center prior to launch.

This information will allow the Made In Space team to make crucial adjustments to a second 3D printer, scheduled for delivery to the ISS in early 2015. This second printer will be an invaluable tool for astronauts and the government. It will also be available to commercial businesses and individuals on Earth to create on-demand hardware such as small satellites.

"In 1957, Sputnik became the first man-made object in space and, 12 years later, that led to humans setting foot on the moon," said Aaron Kemmer, CEO of Made In Space, Inc.. "Now, in 2014, we've taken another significant step forward – we've started operating a machine that will lead us to continual manufacturing in space. Decades from now, people will look back to this event…it will be seen as the moment when the paradigm of how we get hardware to space changed."


Posted in 3D Printing Applications

 

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ugh wrote at 11/27/2014 2:36:28 PM:

Why does she keep calling them "calibration coupons?" That was driving me nuts



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