Topical: Using the International Space Station as a Testbed to Research 3D Printing of Foams
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Alexander Blanchard↗
Engineering topics
Alexander Blanchard
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NASA Technology Maturation Plan for In-space Manufacturing of Metals
As the International Space Station’s (ISS) life approaches its end, NASA intends to travel back to the Moon and establish a sustainable presence, paving a pathway towards Mars. A fundamental shift in the current logistics strategy is required to support extended missions. On-demand manufacturing enables reduced operational cost and increased long term sustainability providing a pathway towards reducing NASA’s logistics burden. The In-Space Manufacturing (ISM) portfolio at Marshall Space Flight Center is developing additive polymers, metals, and electronics manufacturing technologies to enable a sustainable presence on the Moon and enable long-duration transit missions. Manufacturing systems for in-space applications must meet a unique set of constraints requiring a maturation path independent from processes targeted for terrestrial use. In May 2023, the On Demand Manufacturing of Metals (ODMM) project, part of the ISM portfolio funded through the Game Changing Development (GCD) program office, was canceled; however, prior to cancelation, the engineering team developed a technology maturation plan for in-space manufacturing of metallic components. The status of ODMM at closeout and an overview of the technology maturation plan for ODMM are discussed.
In Space Manufacturing↗
NASA’s Comprehensive Databases for Materials Selection (MAPTIS) and Low-Gravity Experiments (PSI)
In the realm of advancing technological change the convergence of materials science and scientific inquiry stands as a testament to humanity’s insatiable curiosity. To assist in this endeavor the National Aeronautics and Space Administration (NASA) provides curated access to two unique databases. Physical Sciences Informatics (PSI) is an online database that houses completed physical science reduced-gravity experiments. Whereas Materials and Processes Technical Information System (MAPTIS) contains several other databases that relate to aerospace materials and processes. Equipped with curated access to these databased provided by the NASA scientists and engineers are furnished with invaluable resources needed to propel technological change.
PSI↗
Development of Aluminum Feedstock for Additive Manufacturing
The rapid evolution of materials science and manufacturing technologies in recent years has offered new pathways to manipulate materials for bespoke manufacturing. Here we aim to develop feedstocks for applications such as radiator panels, fuel tanks, and structural components for outfitting. As a strong, light weight and thermally conductive material aluminum is ideal for these applications. An often-overlooked source of aluminum waste is food packaging used on the International Space Station. Reusing this waste stream will reduce the cost and logistics of regular sparing. In Space Manufacturing (ISM) will utilize this technology is such areas as sparing and outfitting. However, processing aluminum can present challenges, especially in the context of additive manufacturing and sintering, due to its high reactivity and tendency to form a tenacious oxide layer. Identifying appropriate binders and sintering profiles can overcome these challenges. Herein we present our work on obtaining aluminum powder derived from food packaging, binder selection for aluminum feedstock, and a demonstration of bound metal deposition printing.
aluminum↗