An Overview Of NASA’s In-Space Manufacturing Project

Modeling work on FDM (NASA Ames ResearchCenter) Slide credit: Dr. Dogan Timucin, Ames Research CenterObjective is to model FDM process in space(initially for ABS) and predict structuralproperties of the manufactured partsUse physics based analysis of FDM todetermine what physics phenomena may bedistinct in space-based manufacturingDeveloped FE model in ANSYS CFX forcoupled fluid flow and heat conductionproblem associated with filament extrusionand deposition Uses ABS parameters available in theliteraturePerformed qualitative analysis of interdiffusion between two molten roads based onpolymer reputation theory for long-chainmoleculesConcluded that the reputation time is muchsmaller than the time to cool down to glasstransition temperature Filaments can be assumed perfectlyweldedNo significant changes in road shape,filament temperature distribution, dieswell, or evolution of temperature profilenoted in modeling and simulation due tovariation in gravity parameter14AES Mid-Year Review April 2016

Modeling work on FDM (NASA Ames ResearchCenter)Structural Modeling of Macroscopic FDM parts Modeled FDM parts as a composite cellular structure with knownmicrostructure (as determined from the deposition processmodel) Effective structural parameters of the part were studiedanalytically based on classical homogenization and laminatetheories Developed a finite-element model in ABAQUS to estimate theelastic moduli of representative volume elements or unit cells inorder to verify analytical models Moduli were simulated for different layups, raster orientations, airgap distribution as a function of volume void fraction The part strength was estimated using the Tsai-Wu failurecriterionelasticmodulus as afunction ofvoid fractionAES Mid-Year Review AprilSlide credit: Dr. Dogan Timucin, Ames Research Centerrepresentativevolume elementunit cell FEsimulation201615

ReFabricator from Tethers Unlimited, Inc.:Closing the Manufacturing Loop Technology Demonstration Mission payloadconducted under a phase III SBIR withTethers Unlimited, Inc. Refabricator demonstrates feasibility ofplastic recycling in a microgravityenvironment for long duration missions Refabricator is an integrated 3D printer(FDM) and recycler Recycles 3D printed plastic into filamentfeedstock through the PositrusionprocessRefabricator ETU Environmental testing of engineering testunit completed at MSFC in April Payload CDR completed in mid-June Operational on ISS in 2018AES Mid-Year Review April 201616

Toward an In-Space Metal ManufacturingCapability Made in Space Vulcan unit (phase I SBIR) Integrates FDM head derived from theadditive manufacturing facility (AMF), wireand arc metal deposition system, and a CNCend-mill for part finishingUltra Tech Ultrasonic Additive Manufacturing (UAM)system (phase I SBIR) UAM prints parts by using sound waves toconsolidate layers of metal drawn from foilfeedstock (similar to ultrasonic welding) Solid state process that avoids complexities ofmanagement of powder feedstock Work is to reduce the UAM process’s footprintby designing and implementing a higherfrequency sonotrode Scaling of system also has implications forrobotics and freeform fabricationAES Mid-Year Review April 2016Illustration of UAM process(image courtesy of Ultra Tech)17

Toward a In-Space Metal ManufacturingCapability Tethers Unlimited MAMBA (Metal AdvancedManufacturing Bot-Assisted Assembly) Phase I SBIR Ingot-forming method to process virgin orscrap metal Bulk feedstock is CNC-milled Builds on recycling process developedthrough ReFabricator payloadTechshot, Inc. SIMPLE (Sintered InductiveMetal Printer with Laser Exposure) Phase II SBIR AM process with metal wire feedstock,inductive heating, and a low-poweredlaser Compatible with ferromagnetic materialscurrently Test unit for SIMPLE developed underphase I SBIR; phase II seeks to developprototype flight unitAES Mid-Year Review April 2016Tethers Unlimited MAMBA concept.Image courtesy of Tethers Unlimited.Techshot’s SIMPLE, a small metalprinter developed under a Phase ISBIR. Image courtesy of Techshot.18

Ground-based work on additive electronics evaluating technologies to enable multi-material, on-demand digitalmanufacturing of components for sustainable exploration missions In-house work uses nScrypt printer 4 heads for dispensation of inks and FDM of polymers;also has pick and place capability Development of additively manufactured wireless sensor archetype(MSFC) Printed RLC circuit with coupled antenna Capacitive sensing element in circuit is pressure, temperature,or otherwise environmentally sensitive material Sensing material also developed in-house at MSFC Design of pressure switch for urine processor assembly (UPA) In additive design, switching is accomplished via a pressuresensitive material turning a transistor on when the systemexceeds a certain pressure Work on miniaturization and adaptation of printable electronics formicrogravity environment will continue through two contracts (phase I)awarded under SBIR subtopic In-Space Manufacturing of Electronicsand Avionics Techshot, Inc. (STEPS – Software and Tools for ElectronicsPrinting in Space) Direct write and avionics printing capability for ISS Optomec working on miniaturization of patented Aerosol JettechnologyPrinted wireless humidity sensor(wires attached forcharacterization purposes)nScrypt multimaterial printerAES Mid-Year Review April 201619

Materials Development: Recyclable materials Logistics analyses show the dramatic impact of a recyclingcapability for reducing initial launch mass requirements for longduration missions Current packaging materials for ISS represent a broadspectrum of polymers: LDPE, HDPE, PET, Nylon, PVC Tethers CRISSP (Customizable Recyclable ISS Packaging) seeksto develop common use materials (which are designed to berecycled and repurposed) for launch packaging Work under phase II SBIR Recyclable foam packaging made from thermoplasticmaterials using FDM Can create custom infill profiles for the foam to yield specificvibration characteristics or mechanical properties Cornerstone Research Group (CRG) is working under a phase IISBIR on development of reversible copolymer materials Reversible copolymer acts as a thermally activated viscositymodifier impacting the melt properties of the material Designs have strength and modulus values comparable to orexceeding base thermoplastic materials while maintainingdepressed viscosity that makes them compatible with FDMAES Mid-Year Review April 2016CRISSP (image fromTethers Unlimited)FDM prints usingreclaimed anti-staticbagging film withreversible cross-linkingadditive (image fromCornerstone ResearchGroup)20

Use Scenarios for ISS Fabrication Capabilities:Biomedical applications ERASMUS form Tethers Unlimited Manufacturing modulus for production of medicalgrade plastics, along with the accompanyingsterilization procedures required for subsequent useof these materials Bacteria and viruses can become more virulent in thespace environment and crew’s immune systems maybe compromised Enables reuse of consumables/supplies orconsumables manufactured from recycyled material Senior design project on medical capabilities and ISM Medical industry has traditionally been an earlyadopter of AM Lattice casts are custom designed to fit the patient,waterproof, and provide greater comfort and freedomin movement Scan of limb can be imported into CAD software andcustom mesh/lattice generated Printed in multiple interlocking segments due toprinter volume constraints Given logistical constraints of long duration spaceflight onconsumables and unanticipated issues which may arriveeven with a healthy crew, ISM will continue to exploreevolving capabilities to best serve exploration medicineAES Mid-Year Review April 2016Potential food and medicalconsumables for manufacture andsterilization using the TethersUnlimited ERASMUS systemOne piece of a two piece lattice cast(senior design project)21

3D Printing with Biologically Derived Materials Use biologically derivedfilament materials and/ormaterials from inedible plantmass to create 3D printedsubstrate blocks for plantgrowthCollaborative activitybetween VEGGIEproject/payload at KennedySpace Center, SyntheticBiology team at AmesResearch Center, and Inspace Manufacturing team atNASA MarshallMicrobial cellulose used asseed germinating eMoistureRetainer-Starch polymer3D Printed plant growthblocks from MSFC(PLA/PHA)Seeds allowed togerminate for 3daysAES Mid-Year Review April 201622

ISM Technology Development Road MapAES Mid-Year Review April 201623

Fabrication Laboratory Overview Aligned with vision of in-space manufacturing project to develop and test on-demand,manufacturing capabilities for fabrication, repair and recycling during Exploration missionsISM offers: Dramatic paradigm shift in development and creation of space architectures Efficiency gain and risk reduction for deep space exploration “Pioneering” approach to maintenance, repair, and logistics will lead to sustainable, affordablesupply chain model In order to develop application-based capabilities for Exploration, ISM must leverage thesignificant and rapidly-evolving terrestrial technologies for on-demand manufacturing Requires innovative, agile collaboration with industry and academia NASA-unique Investments to focus primarily on developing the skillsets and processesrequired and adapting the technologies to the microgravity environment and operations Ultimately, an integrated “FabLab” facility with the capability to manufacture multi-materialcomponents (including metals and electronics), as well as automation of part inspection andremoval will be necessary for sustainable Exploration opportunitiesAES Mid-Year Review April 201624

The Multimaterial Fabrication Laboratory forISS (“FabLab”)Power consumption forentire rack is limited to 2000WTypical EXPRESSRack structure Payload mass limit for rackis less than 576 lbmNASA is seeking proposals to provide a feasible design and demonstration of afirst-generation In-space Manufacturing Fabrication Laboratory for demonstrationon the ISSMinimum target capabilities include: Manufacturing of metallic components Meet ISS EXPRESS Rack constraints for power and volume Limit crew time Incorporate remote and autonomous verification and validation of partsProposal window now closedFederal Business Opportunities link to solicitation (closed):www.fbo.gov/index?s opportunity&mode form&tab core&id 8a6ebb526d8bf8fb9c6361cb8b50c1f8AES Mid-Year Review April 201625

The Multimaterial Fabrication Laboratory forISS BAA for multimaterial, multiprocess fabrication laboratory for the International Space StationPhased approach Phase A – scaleable ground-based prototype Phase B – mature technologies to pre-flight deliverable Phase C – flight demonstration to ISSThresholdThe system should have the ability for ondemandmanufacturingofmulti-materialcomponents including metallics and polymersas a minimum.The minimum build envelope shall be 6” x 6” x6”.The system should include the capability forearth-based remote commanding for all nominaltasks.The system should incorporate remote, groundbased commanding for part handling andremoval in order to greatly reduce dependenceon astronaut time.*Thesystemshouldincorporatein-linemonitoring of quality control and post-builddimensional verification.ObjectiveMulti-material capability including variousaerospace-grade metallic,polymer, and/orconductive inks significantly increase the meritof the proposal.As large of a build-volume and/or assemblycapability as possible within the Express Rackvolume constraints listed in Section 3.Remote commanding and/or autonomouscapability for all tasks (nominal and off-nominal.The system should incorporate autonomous parthandling and removal in order to greatly reducedependence on astronaut time.*The system should incorporate in-situ, real-timemonitoring for quality control and defectremediation capability.* Astronaut time is extremely constrained. As a flight demonstration, the ISM FabLab would be remotelycommanded and operated from the ground, with the ultimate goal being to introduce as much eventual autonomyas possible. As a minimum, there should be no greater than 15 minutes of astronaut time required for any givennominal activity, with the end-goal being to apply the same rule to maintenance and off-nominal operations aswell.AES Mid-Year Review April 201626

Student Projects Future Engineers, collaboration between NASA andAmerican Society of Mechanical Engineerschallenges K-12 students to design space hardwarethat can be 3D printed: www.futureengineers.org Think Outside the Box Challenge (endedOctober 2016) Mars Medical Challenge (ended March 2017) Two for the Crew Challenge (currently open) Senior design projects Material property database and design of a 3Dprinted camera mount for Robonaut (20152016) Design of a 3D printed parametric tool kit anddynamic user interface for crew use (20162017) Feasibility study of 3D printing of lattice casts(alternative to SAM splint procedure andtraditional casts) – (2016-2017) Crew health and safety toolkit (2017-2018) 3D printed plant substrates (2017-2018) NASA XHab university projects Student teams apply NASA systemsengineering practices to develop hardware 2016-2017 projects with University ofConnecticut and University of MarylandAES Mid-Year Review AprilVanderbilt UniversitySenior DesignPictured: 3D printedlattice cast segmentUniversity of ConnecticutXHab: Design of anintegrated recycler andprinter for ISSUniversity of Maryland: 3D Printing ofSpacesuit components (pictured: 3-elementwedge for elbow)201627

In-Space Manufacturing Photo Album (2017)AES Mid-Year Review April 201628

Collaborators Niki Werkheiser, In-Space Manufacturing Project Manager Dr. Raymond “Corky” Clinton, Deputy Manager, NASA MSFCScience and Technology Office Zach Jones, Manufacturing Engineer for ISM Dr. Frank Ledbetter, Senior Technical Advisor for In-SpaceManufacturing Dr. Dogan Timucin and Dr. Kevin Wheeler, Ames ResearchCenter Personnel who worked on testing and analysis of materials: Dr. Terry Rolin (CT) Dr. Ron Beshears (CT) Ellen Rabenberg (SEM) Cameron Bosley (mechanical test) Dr. Richard Grugel (SEM) Tim Huff (FTIR) Lewis “Chip” Moore (surface metrology)AES Mid-Year Review April 201629

References1. Owens, A.C. and O. DeWeck. “Systems Analysis of In-Space Manufacturing Applications forInternational Space Station in Support of the Evolvable Mars Campaign.” Proceedings of AIAASPACE 2016 (AIAA 2016-5034). http://dx.doi.org/10.2514/6.2016-53942. Prater, T.J., Bean, Q.A., Werkheiser, N., et al. “Summary Report on Results of the 3D Printingin Zero G Technology Demonstration Mission, Volume 1.” NASA/TP-2016-219101 NASATechnical Reports Server. http://ntrs.nasa.gov/search.jsp?R 201600089723. Prater, T.J., Bean, Q.A., Werkheiser, N., et al. “Analysis of specimens from phase I of the 3DPrinting in Zero G Technology demonstration mission.” Rapid Prototyping Journal (in queuefor publication)4. Prater, T.J., Bean, Q.A., Werkheiser, N., et al. “A Ground Based Study on Extruder StandoffDistance for the 3D Printing in Zero G Technology Demonstration Mission.” (in queue forpublication on NASA Technical Reports Server in June 2017)5. Prater, T.J., Bean, Q.A., Werkheiser, N., et al. “NASA’s In-Space Manufacturing Initiative: InitialResults from the International Space Station Technology Demonstration Mission and FuturePlans.” Proceedings of the 2016 National Space and Missile and Materials Symposium.6. In-Space Manufacturing (ISM) Multi-Material Fabrication Laboratory (FabLab). SolicitationNumber: NNHZCQ001K-ISM-FabLab.https://www.fbo.gov/index?s opportunity&mode form&tab core&id 8a6ebb526d8bf8fb9c6361cb8b50c1f8AES Mid-Year Review April 201630

Extra slides: Centennial Challenge on 3DPrinting of HabitatsAES Mid-Year Review April 201631

Potential of 3D Printing Technologies for Space and Earth Autonomous systems can fabricate infrastructure(potentially from indigenous materials) on precursormissions Can serve as a key enabling technology for exploration by reducinglogistics (i.e. launch mass) and eliminating the need for crewtending of manufacturing systems Also has potential to address housing needs in light ofunprecedented population growth Disaster response Military field operationsArtist’s rendering ofmanufacturingoperations on aplanetary surface

Centennial Challenge: 3D Printed HabitatObjective: Advance additive construction technology neededto create sustainable housing solutions for Earth and beyondAutonomous, Sustainable Additive Manufacturing of HabitatsPhase 1Phase 2Phase 3Design:Develop state-of-the-artarchitectural concepts thattake advantage of the uniquecapabilities offered by 3Dprinting.Structural Member:Demonstrate an additivemanufacturing materialsystem to create structuralcomponents usingterrestrial/space basedmaterials and recyclables.On-Site Habitat:Prize Purse Awarded: 0.04MPrize Purse: 1.1MBuilding on materialtechnology progress fromPhase 2, demonstrate anautomated 3D Print Systemto build a full-scale habitat.Mars Ice House, winner of the Phase I competition from SpaceExploration Architecture and Clouds AO

Phase II Competition: Level 3Results1st place, 250,000:Branch Technology andFoster Partners2nd place, 150,000:Penn State University

Antenna Feed Horn: collaboration between NASA Chief Scientist & Chief Technologist for Space Communications and Navigation, ISM & Sciperio, Inc. Printed 3/9/17 and returned on SpaceX-10 3/20/17. OGS Adapter: adapter attaches over the OGS air outlet and fixtures the veloci