Updated by Reginald Davey 16/01/2024
Astronauts have to spend extended periods of time in space. Replacing broken equipment in a timely fashion is all but impossible unless the parts are already onboard. However, one emerging technology promises to completely solve this problem: 3D printing.
The 3D Printer during testing in the Microgravity Science Glovebox. (NASA Image)
The Cost of Sending Equipment into Space
Space travel is an incredibly risky endeavor. Equipment that could, if it breaks, cause potentially fatal consequences is not easy to replace on long missions. There are always obstacles and emergencies that cannot be adequately prepared for. The cost of transporting equipment to a spacecraft such as the International Space Station can reach thousands of dollars per pound of equipment (payload), depending on the launch vehicle.
Building this equipment on Earth and then launching it into space is much less efficient than it would be to simply build the equipment in space. Indeed, reducing the staggering costs involved with sending new payloads to astronauts is a central concern for space agencies like NASA and ESA.
Printing 3D Parts in Space
Having 3D printers on board a spacecraft would allow the astronauts much greater versatility in their ability to handle any emergencies that arise and would allow them greater versatility in their missions.
3D printers essentially print out a material layer by layer until, eventually, a fully three-dimensional object is created. The materials used are normally a heated plastic or a heated metal, although, in certain cases, 3D printers use other materials.
However, the unique demands caused by operating in outer space mean that there are some key challenges associated with the use of 3D printers. For instance, it affects material choice: plastic is an extremely lightweight substance, which makes it more attractive as it reduces payload weight.
Made In Space 3D Printing Showcase - REAL2015 Interviews
Video Credit: Autodesk Reality Computing | YouTube.com
Self-Replicating 3D Printers in Space
3D printers can be used for many different applications and as such are incredibly useful to have on a spacecraft.
If a part were to break in space or during a 'long term’ space mission, such as a mission to Mars, the astronauts on board would have to wait for another spacecraft to bring them the part. However, an on-board 3D printer could print the spare part straight away.
A 3D printer could even be able to create replacement parts for itself if an astronaut were to notice that some of its parts were deteriorating. Rather than bringing a toolbox, astronauts could just bring a 3D printer capable of printing the tools they find they need during the course of the mission.
Made in Space: The First 3D Printer in Space
NASA tested the potential of 3D printing on board the International Space Station (ISS) in 2014. The company that built the printer for use in the investigation was Made in Space which was acquired by Redwire, and the printer used fused filament fabrication (FFF) to create 3D objects out of plastic.
Dozens of 3D-printed parts were produced, including a ratchet. Parts printed onboard the ISS were compared with identical parts produced back on Earth. By comparing the two, researchers concluded that microgravity had a negligible engineering effect on the process
Thus, the 2014 project aboard the ISS demonstrated that 3D printing was a viable option for long-term space missions. A notable finding was that 3D printing in space made it easier to produce parts that would otherwise be affected by Earth’s gravity during the additive manufacturing process.
Parts printed included antennas and adaptors. Crucially, the team demonstrated the viability of sending designs remotely from Earth to space-based assets. Furthermore, they have stated that recycled materials could be used to produce parts, further reducing the space needed to store them onboard, making the process self-sustaining.
Printing Parts with Metal
Building on the knowledge gained by previous efforts, scientists have concentrated on space-based additive manufacturing due to its immense benefits in terms of cost, time, and versatility.
However, whilst Made in Space’s project demonstrated the viability of this technology, it was limited to using plastic feedstocks, which may not be suitable for all types of equipment on a long space mission.
The European Space Agency (ESA) has explored printing metal parts onboard the ISS, with a 3D printer sent to the station in February 2023. This solution uses directed energy deposition (DED) to print parts from metal wire. Companies including AddUp and Airbus Defence and Space were involved in the project.
Contained wire spools, which are used in DED processes, provide some benefits over powder, which can spill or present an explosion hazard onboard spacecraft. Furthermore, plastic is not suitable for structural elements or other equipment which must be constructed of metal.
The feedstock material used is 316L stainless steel, which is commonly used in a wide array of applications. This makes the Metal3D printer potentially a very versatile solution that can be used to produce distinct parts in a single system.
Much like Made in Space’s earlier efforts, a printer on Earth will be used to produce identical parts to evaluate the effects of microgravity on the metal printing process. It is hoped that there will be very few difficulties with the system, further demonstrating the viability of 3D printing in space.
Made In Space and CASIS: Launch world's first 3D printer to space
Video Credit: ISSCASIS | YouTube.com
In Summary
3D printing in space is an exciting technological frontier. By leveraging the power of this emerging technology, NASA and other space agencies hope to reduce costs and provide astronauts with the ability to produce and replacemission critical equipment in a fraction of the time needed currently.
It will be interesting to see where the technology goes next as crewed missions to Mars and other planetary bodies in the Solar System move closer to reality, presenting their own unique challenges for innovation. A zero G 3D printer could become one of the central technologies in the future space race.
References and Further Reading
Made In Space - Medium.com
Off-World Manufacturing is Here - Made In Space
Space Station 3-D Printer Builds Ratchet Wrench To Complete First Phase Of Operations - NASA
3D Printing In Zero-G Technology Demonstration - NASA
MADE IN SPACE BLOG - Made In Space
Advanced Space Transportation Program: Paving the Highway to Space - NASA
Press Kit - Made In Space
NASA (2019) Solving the Challenges of Long Duration Space Flight with 3D Printing [online] nasa.gov. Available at:
https://www.nasa.gov/mission_pages/station/research/news/3d-printing-in-space-long-duration-spaceflight-applications
Peels, J (2022) Space Metal 3D Printer Heads to ISS in 2023 [online] 3dprint.com. Available at:
https://3dprint.com/289836/space-metal-3d-printer-to-head-to-iss-in-2023
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