Designing for Additive Manufacturing in the Space Industry
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Polit-Casillas, Raul↗
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Simulation and Testing of Additive Manufacturing Processes for Space Applications
UNKNOWN
Quadrelli, Marco B.↗
Powering the Next Frontier: Manufacturing Solar Cells in Space
In support of NASA's Artemis program with the goal of a sustained human-lunar presence, there is a need for very large (>100kW) and high-voltage-capable solar arrays, estimated to cost over $150M. Perovskite-based thin-film photovoltaics offer substantial advantages over state-of-the-art solar arrays from the perspective of manufacturing large arrays. Many of the challenges perovskite solar cells experience in terrestrial operations, e.g degradation caused by moisture and oxygen exposure, are not applicable in long-term space applications. The future of implementing perovskite photovoltaics in space is promising, further so is manufacturing these solar cells in space. Here we provide an overview of NASA Glenn Research Center's progress towards validating perovskite solar cells for operation in space and we illuminate innovation opportunities to which the greater community can contribute so that we may realize in-space manufacturing of perovskite photovoltaics.
Solar Cells↗
Manufacturing and quality control requirements for space systems electrical harnesses
Manufacturing and quality control requirements for space vehicle electrical harnesses
QUALITY CONTROL↗
Needs and Opportunities in the Development of Advanced Materials and Manufacturing Methods for Future Long-Duration Human Space Exploration
Weight, functionality, and sustainability are all critical concerns for future, long-duration, human exploration of space. Exploration missions will be mass-limited, since the amount of supplies and instruments that future astronauts will be able to take with them will be limited by launch vehicle and spacecraft mass and efficiency. Astronauts will need to have the capability to repair or replace worn-out or broke hardware and produce new components to be able to function for long periods at locations far-removed from Earth. Ultra-lightweight, multifunctional materials will be required to enable significant reductions in launch vehicle, spacecraft, and habitat mass in order to maximize payload. "Mass-less Exploration" concepts must be developed that will recycle materials and waste and convert available planetary materials into new feedstock materials and utilize in-space additive manufacturing to use these materials to produce the
composites↗
Accelerating Materials Discovery for National Security
Explore the source record for details and available documents.
In space manufacturing↗
Application of Temperature-Controlled Thermal Atomization for Printing Electronics in Space
Additive Manufacturing (AM) is a technology that builds three dimensional objects by adding material layer-upon-layer throughout the fabrication process. The Electrical, Electronic and Electromechanical (EEE) parts packaging group at Marshall Space Flight Center (MSFC) is investigating how various AM and 3D printing processes can be adapted to the microgravity environment of space to enable on demand manufacturing of electronics. The current state-of-the art processes for accomplishing the task of printing electronics through non-contact, direct-write means rely heavily on the process of atomization of liquid inks into fine aerosols to be delivered ultimately to a machine's print head and through its nozzle. As a result of cumulative International Space Station (ISS) research into the behaviors of fluids in zero-gravity, our experience leads us to conclude that the direct adaptation of conventional atomization processes will likely fall short and alternative approaches will need to be explored. In this report, we investigate the development of an alternative approach to atomizing electronic materials by way of thermal atomization, to be used in place of conventional aerosol generation and delivery processes for printing electronics in space.
Wu, Chih-Hao↗
A review of manufacturing environmental controls at Marshall Space Flight Center.
Environmental control manufacture discussing cleaning, design and maintenance problems, historical background, etc
SPACECRAFT ENVIRONMENT↗
Ideas For Infusing In-Space Servicing, Assembly and Manufacturing Concepts into Nuclear Electric Propulsion Architectures
NASA is currently investigating nuclear electric propulsion (NEP) for human Mars transport within the space nuclear propulsion portfolio. NEP spacecraft have the following characteristics, they: 1) include very large structures (~100-meter length); 2) are comprised of many components/modules; and 3) have very long lifetimes (e.g., 50 years for fuel rods). Thus, NEP spacecraft can be classified as a “persistent asset,” which is any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. NEP spacecraft will benefit from taking advantage of, and incorporating, In-space Servicing, Assembly, and Manufacturing (ISAM) capabilities in the spacecraft architecture from the onset, enabling system maintenance, repair, and evolution. ISA has a long history of being proposed for, and studied as, a means for achieving large systems in space. More recently, the benefits of ISA have been recognized by NASA, the Department of Defense (DOD), other government agencies, and commercial space companies, and thus, ISAM is being actively pursued at a national level. Past and current strategies for achieving large structures in space have relied largely on two strategies; the first is to launch monolithic structures (designed to meet launch vehicle requirements for payload size and mass) that are docked or berthed to other monolithic structures on-orbit to form a larger structure (e.g., the International Space Station [ISS]); the second is folding and packaging large structures to fit inside a payload fairing and deploying the full-sized structure (unaided) once on-orbit (e.g., the James Webb Space Telescope [JWST]). To date, conceptual architecture studies performed for NEP spacecraft capable of human-rated Mars transport have only included a combination of the two previously mentioned strategies. This paper will propose ideas for infusing ISAM strategies into NEP vehicle architectures that leverage existing and near future technologies and enable the resulting NEP systems to be realized in a more time- and cost-efficient manner.
in-space assembly↗
Space Environmental Effects on Additively Manufactured (AM) Parts on MISSE-9/10
The Materials on International Space Station Experiment (MISSE) experiments have made a continuous presence on the ISS and allowed for testing of performance and durability of materials exposed to the Low Earth Orbit (LEO) space environment. Additive Manufacturing (AM) has been included on several MISSE flights, and many companies (Made in Space and Stratasys) and NASA centers wanted to test various AM material samples. The goal of studying Space Environmental Effects on AM Parts with MISSE 9/10 was to fly promising metal and polymer AM material samples (dogbones) that could have future manufacturing capabilities in space and conduct post-flight analysis of these materials via mechanical and optical properties. On these flights, MISSE-9 contained three Inconel and 12 polymer samples and MISSE-10 included three Inconel and 16 polymer samples. Before flying to the ISS, all the samples underwent thermal vacuum bakeout (at 60°C for 24 hours and 10-6 torr). After bakeout, control and flight experiments were weighed, and optical properties were taken. Optical properties such as solar absorptance and infrared emittance were taken on the control samples and the flight samples (preflight and postflight). To understand more about the mechanical properties of the AM samples, tensile testing was conducted on the samples to determine the yield and ultimate tensile strength of the dogbone samples against the control. Lastly, the torque on the fasteners securing the dogbone samples were loosened and measured using a torque wrench, and they were compared to their preflight torque specification required. Optical properties and masses were recorded before flight, and the postflight results were recorded and collected in June 2022 to study the effects. With the postflight analysis, NASA engineers can now better characterize how UV radiation and thermal cycling affect the material properties.
Materials on International Space Station Experimen↗
Ideas for Infusing In-Space Servicing, Assembly, and Manufacturing Concepts into Nuclear Electric Propulsion Architectures
NASA is currently investigating nuclear electric propulsion (NEP) for human Mars transport within the space nuclear propulsion portfolio. NEP spacecraft have the following characteristics, they: 1) include very large structures (~100-meter length); 2) are comprised of many components/modules; and 3) have very long lifetimes (e.g., 50 years for fuel rods). Thus, NEP spacecraft can be classified as a “persistent asset,” which is any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. NEP spacecraft will benefit from taking advantage of, and incorporating, In-space Servicing, Assembly, and Manufacturing (ISAM) capabilities in the spacecraft architecture from the onset, enabling system maintenance, repair, and evolution. ISA has a long history of being proposed for, and studied as, a means for achieving large systems in space. More recently, the benefits of ISA have been recognized by NASA, the Department of Defense (DOD), other government agencies, and commercial space companies, and thus, ISAM is being actively pursued at a national level. Past and current strategies for achieving large structures in space have relied largely on two strategies; the first is to launch monolithic structures (designed to meet launch vehicle requirements for payload size and mass) that are docked or berthed to other monolithic structures on-orbit to form a larger structure (e.g., the International Space Station [ISS]); the second is folding and packaging large structures to fit inside a payload fairing and deploying the full-sized structure (unaided) once on-orbit (e.g., the James Webb Space Telescope [JWST]). To date, conceptual architecture studies performed for NEP spacecraft capable of human-rated Mars transport have only included a combination of the two previously mentioned strategies. This paper will propose ideas for infusing ISAM strategies into NEP vehicle architectures that leverage existing and near future technologies and enable the resulting NEP systems to be realized in a more time- and cost-efficient manner.
in-space assembly↗
In-space Servicing, Assembly, and Manufacturing (ISAM) State of Play - 2024 Edition
This annual document characterizes the current state of in-space servicing, assembly, and manufacturing.
Dale Arney↗
In-space Servicing, Assembly, and Manufacturing (ISAM) State of Play 2022 Edition
The future of spaceflight will yield increasingly more ambitious missions to support civil, national security, and commercial space sectors. Achieving these ambitious missions is not feasible using the traditional paradigm of launching an integrated, fully functioning system on a single launch vehicle. For example, science and human exploration missions will desire payloads that are larger than any foreseeable launch vehicle fairing, national security missions will require persistent assets that are mobile and resilient, and commercial space missions will require cost-effective ways to update to the latest technology on orbit. In-space Servicing, Assembly, and Manufacturing (ISAM) can vastly expand the performance, availability, and lifetime of space systems compared to the traditional paradigm of launching an asset with no intent to ever touch it again. ISAM capabilities foster an ecosystem that changes the space operations paradigm, creating the foundation for sustainable exploration and serving as a multiplier for other capabilities like space logistics, power generation, and reusability. Previous achievements in ISAM have enabled ambitious human and robotic space missions. NASA’s International Space Station (ISS) operations and maintenance, servicing missions of the Hubble Space Telescope (HST), and Northrop Grumman’s Mission Extension Vehicle (MEV) demonstrate the dramatic operational missions that can be achieved using ISAM capabilities. Many current and upcoming flight demonstrations are advancing areas that will enable the next generation of civil, national security, and commercial space missions. This document describes the current state of ISAM missions, capabilities, and developments. Compiling and organizing the available ISAM capabilities will help mission designers incorporate ISAM technologies into their concepts, create the starting point for technology development plans and roadmaps, and provide technologists a survey of the field they are developing. This document divides the ISAM capabilities into 11 capability areas that describe the functions or activities that would be performed in space using ISAM. This version of the ISAM State of Play is part of a continuing journey to encourage the use of ISAM capabilities in space. Compiling and organizing the current state of ISAM provides a simple resource for those working in the ISAM ecosystem to ensure that the advancements being made build upon the investments of the past. The state of play is ever changing as new capabilities are developed, and this document will be periodically updated to ensure that it is relevant to those who need it in the future.
ISAM↗
Autonomous In-Space Servicing, Assembly, and Manufacturing (ISAM) at NASA Langley
Explore the source record for details and available documents.
in-space assembly↗
Total Quality Management in Space Shuttle Main Engine manufacturing
The Total Quality Management (TQM) philosophy developed in the Marshall Space Flight Center (MSFC) is briefly reviewed and the ongoing TQM implementation effort which is being pursued through the continuous improvement (CI) process is discussed. TQM is based on organizational excellence which integrates the new supportive culture with the technical tools necessary to identify, assess, and correct manufacturing processes. Particular attention is given to the prime contractor's change to the organizational excellence management philosophy in SSME manufacturing facilities.
Ding, J.↗
Cold Metal Transfer (CMT) Wire-Arc Additive Manufacturing (WAAM)
Aluminum has been identified as a compound within regolith and is likely to become a core component of our infrastructure on the lunar surface as in-situ resource utilization (ISRU) capabilities are advanced Large-scale components, outfitting, and repairs of aluminum materials can be fabricated with robotic wire arc additive manufacturing (WAAM) in order to inhabit the moon’s surface long term WAAM is a high value process for lunar advanced manufacturing as it does not require special containment to reduce explosion hazards such as powder-based additive processes and feedstock The welding process of cold metal transfer (CMT) is a relatively new variation of gas metal arc welding (GMAW, also known as MIG) that relies on the detection of a short circuit in the welding process to control the deposition droplet action, resulting in lower heat input and splatter compared to conventional MIG welding The past year was spent developing the CMT-WAAM process for aluminum materials, tested specialty feedstock, tested within the high vacuum environment, and advanced the MSFC capability to perform complex toolpathing from solid models Upcoming and future work includes large depositions working towards material certification for multiple feedstocks, in-situ monitoring, work to use recycled materials for the AM feedstock, and the design and fabrication of a parabolic flight experiment payload.
cold metal transfer↗
NASA's Office Safety Mission Assurance Efforts to Improve Non-destructive Evaluation Methods for Additive Manufacturing and In-Space Inspection
National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the Moon and Mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward, inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency, as well as providing highlights for points of infusion for helping NASA meet its future mission goals.
NDE↗
Space Environmental Effects on Additively Manufactured Materials – Results from MISSE-9 and MISSE-10
The NASA Marshall Space Flight Center (MSFC) Space Environmental Effects (SEE) and Contamination Control (CC) teams prepared and characterized MISSE-9 and MISSE-10’s additively manufactured (AM) materials samples to investigate the effect of ultraviolet (UV) radiation, thermal cycling, outgassing, and temperature and provide data on the durability of these samples. Materials studied were polyetherimide (Ultem 1010 and 9085), electrostatic dissipative polyetherketoneketone (ESD-PEKK), also known commercially as Antero 840CN03, polycarbonate biocompatible per ISO 10993 USP Class VI (PC-ISO), and Inconel 718. Some samples were manufactured at MSFC, while 3D printer manufacturers Stratasys and Made In Space, Inc. (MIS) (now Redwire) participated in this effort to compare different vendors and printing setups. Results from nondestructive analyses and tensile testing are presented.
additive manufacturing↗