3D Printing In Zero-G Technology Demonstration (3D Printing In Zero-G) - 09.17.14

Overview | Description | Applications | Operations | Results | Publications | Imagery
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The 3D Printing In Zero-G Technology Demonstration (3-D Printing In Zero-G) experiment demonstrates that a 3-D printer works normally in space. In general, a 3-D printer extrudes streams of heated plastic, metal or other material, building layer on top of layer to create three-dimensional objects. Testing a 3-D printer using relatively low-temperature plastic feedstock on the International Space Station is the first step towards establishing an on-demand machine shop in space, a critical enabling component for deep-space crewed missions and in-space manufacturing.  

Science Results for Everyone
Information Pending



The following content was provided by Ken Cooper, B.A. in Mechanical Engineering, and is maintained in a database by the ISS Program Science Office.

Experiment Details

OpNom 3D Printing In Zero-G

Principal Investigator(s)

  • Ken Cooper, B.A. in Mechanical Engineering, Marshall Space Flight Center (MSFC), AL, United States

  • Co-Investigator(s)/Collaborator(s)
  • Michael P. Snyder, M.S. Aeronautical & Astronautical Engineering, Made in Space, Moffett Field, CA, United States
  • Jason J. Dunn, M.S. Aerospace Engineering, Made in Space, Moffett Field, CA, United States

  • Developer(s)
    Marshall Space Flight Center, Huntsville, AL, United States

    Made In Space, Inc., Moffett Field, CA, United States

    Sponsoring Space Agency
    National Aeronautics and Space Administration (NASA)

    Sponsoring Organization
    Technology Demonstration Office (TDO)

    Research Benefits
    Information Pending

    ISS Expedition Duration
    September 2014 - October 2015

    Expeditions Assigned
    41/42,43/44

    Previous ISS Missions
    Information Pending

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    Experiment Description

    Research Overview

    The 3D Printing In Zero-G Technology Demonstration serves as a proof-of-concept test of the properties of melt deposition modeling additive manufacturing in the microgravity environment of the International Space Station (ISS).  The lessons learned from this technology demonstration will be applied in the next generation of melt deposition modeling in the permanent NanoRacks Additive Manufacturing Facility (AMF), as well as for any future additive manufacturing technology.  This includes any future additive manufacturing technologies NASA may plan to use, such as metals or electronics in-space manufacturing, on both the ISS and Deep Space Missions.  This demonstration is the first step towards realizing a machine shop in space, a critical enabling component of any Deep Space Mission.  The 3D Printing In Zero-G payload is a product of commercial company Made In Space, Inc. (MIS), and will be acquired by NASA through a Small Business Innovative Research (SBIR) Phase III contract.  The project’s goal is to raise the technology readiness level (TRL) of the 3D Printing In Zero-G printer technology from 5 to 6, making it the first demonstration of additive manufacturing in space.  In addition, the lessons learned are infused into industry with the production of the permanent Additive Manufacturing Facility (AMF).

    This project provides:

    • The first demonstration of additive manufacturing in space
    • A detailed analysis of how acrylonitrile butadiene styrene (ABS) thermoplastic resin behaves in microgravity
    • A comparison between additive manufacturing in Earth’s gravity and in consistent, long-term exposure to microgravity (insufficient in parabolic flights due to “print-pause” style of printing)
    • Advance the TRL of additive manufacturing processes to provide risk reduction, and capabilities, to future flight or mission development programs
    • The gateway to fabricating parts on-demand in space, thus reducing the need for spare parts on the mission manifest
    • A technology with the promise to provide a significant return on investment, by enabling future NASA missions that would not be feasible without the capability to manufacture parts in situ
    • The first step towards evolving additive manufacturing for use in space, and on Deep Space Missions.

    Description

    In addition to safely integrating into the Microgravity Science Glovebox (MSG), the 3D Print requirements include the production of a 3D multi-layer object(s) that generate data (operational parameters, dimensional control, mechanical properties) to enhance understanding of the 3D printing process in space.  Thus, some of the prints were selected to provide information on the tensile, flexure, compressional, and torque strength of the printed materials and objects.  Coupons to demonstrate tensile, flexure, and compressional strength were chosen from the American Society for Testing and Materials (ASTM) standards.  Multiple copies of these coupons are planned for printing to obtain knowledge of strength variance and the implications of feedstock age.  Each printed part is compared to a duplicate part printed on Earth.  These parts are compared in dimensions, layer thickness, layer adhesion, relative strength, and relative flexibility.  Data obtained in the comparison of Earth- and space-based printing are used to refine Earth-based 3D printing technologies for terrestrial and space-based applications.

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    Applications

    Space Applications

    3-D printing serves as a fast and inexpensive way to manufacture parts on-site and on-demand, reducing the need for costly spares on the International Space Station and future spacecraft. Long-term missions would benefit greatly from having onboard manufacturing capabilities. Data and experience gathered in this demonstration will improve future three-dimensional manufacturing technology and equipment for the space program, allowing a greater degree of autonomy and flexibility for astronauts.

    Earth Applications

    The experiment compares 3-D printed objects made on Earth with those made in microgravity. Insight into how 3-D printing works in microgravity could improve 3-D printing methods for industry. The experiment includes student activities, in particular a project allowing students to design items to be 3-D printed on the space station by crew members.

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    Operations

    Operational Requirements

    • 28V dc power supplied by MSG.  200W cooling capability from MSG air circulation.
    • Crew required to remove prints from print tray and bag prints after a print is completed.  Also required for maintenance of the printer, from changing the feedstock cartridge to replacing a clogged print head or electronics box.
    • Video camera monitoring of the printing process through 3D Print’s polycarbonate windows from the ground.
    • Interface with MSG laptop, uplink capability for 21st planned print.

    Operational Protocols

    Control of the printer hardware includes: software on the MSG laptop, uplink from the ground, and a physical on/off switch on the printer.  Video monitoring of the printing process is conducted from the ground.  A concept of operations and training video will accompany the printer.

     

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    Results/More Information
    Information Pending

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    Results Publications

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    Ground Based Results Publications

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    ISS Patents

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    Related Publications

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    Related Websites
    Made in Space

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    Imagery

    image

    Michael Snyder and Aaron Kemmer monitoring the performance of extruders inside the Made In Space experiment box during a microgravity portion of flight aboard a modified Boeing 727 from the Zero G Corporation.
    Image credit:  Made In Space, Inc.


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    image The 3D Printer during testing in the Microgravity Science Glovebox (MSG) Engineering Unit at Marshall Space Flight Center.
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    image

    Jason Dunn and Mike Snyder (Made in Space, Inc.) assembling the 3D Printer in the Made in Space cleanroom at Ames Research Park.


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