Large-scale Additive Manufacturing for Exploration

Paul Gradl

NASA NTRS · 20220000488

Large-scale Additive Manufacturing for Exploration

Abstract

Additive Manufacturing (AM) is emerging as a mainstream manufacturing technology, and demand for large part manufacturing is getting stronger. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. This webinar focuses on additive manufacturing of NASA’s RS-25 engine nozzle liner using DMD technology. This liner (10ft in height and 8ft in diameter) is beyond the print capability of existing 3D printing processes. To print this part, significant advancements were made to the DMD technology by deploying two process heads in the machine and expanding the machine work envelop to allow manufacturing of such large parts in a safe and efficient environment. A successful demonstration of the AM of the RS25 engine nozzle liner marks a new era in 3D printing and elevates the current 3D printing technology to a new level for affordable manufacturing of large metal parts.

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Additive Manufacturing Directed Energy Deposition DED

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Paul Gradl. Large-scale Additive Manufacturing for Exploration. https://ntrs.nasa.gov/citations/20220000488

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