Researchers from Technical University of Braunschweig (TUB) have proposed to mount 3D printers on satellites to allow additive manufacturing in space.
The reasoning behind the proposal is due to current spacecraft size being restricted by rocket fairing dimensions, requiring complex, costly assembly or folding methods for larger structures. An alternative is in-space manufacturing (ISM) using additive manufacturing, allowing the creation of larger, more efficient designs without needing to endure launch stresses.
AM’s low waste and flexibility make it suitable for ISM, with experiments like the Additive Manufacturing Facility on the ISS showcasing feasibility. Missions such as Orbital Factory II and OSAM-2 plan to expand AM to larger, functional structures in space.
FDM is particularly promising for ISM due to its suitability for microgravity, absence of liquids or powders, and lower thermal requirements. This method enables the creation of sparse, load-efficient structures like trusses, critical for large space systems.
The proposed method involves using a free-flying satellite equipped with a robotic manipulator and FDM printhead to manufacture large structures in segments, which are then assembled. This concept has been tested in a simulated microgravity environment using a fan-propelled robot on an air bearing table, demonstrating the potential for manufacturing unlimited-length structures in space.
The TUB method offers a significant advancement in ISM, combining the flexibility of AM with the benefits of a microgravity environment for efficient, large-scale space structure manufacturing.
Source: frontiersin.org