3D Printers on the International Space Station Presenter: Matthew Napoli

1 Digital Deliveries

2 Why manufacture on the ISS?

3 STEM low cost access to space

4 Background on Made In Space

MIS Founded in 2010 to Build AM tech for Space ● Identified extrusion printing as a low cost, low mass solution that could be implemented within a few years ● 3 goals: Study 3D Printing, Test in Micro-g, and Fly 3D Printer on ISS Conducted Multiple Trade Studies on AM in Space ● COTS Components, Extrusion Printers ● Metal AM, Space Qualified Polymers, Robotic Assembly MIS has an Innovative 3D Printing Lab ● More than a dozen OTS and custom 3D printers ● Testing unique functionalities and capabilities ● 30,000+ hours of extrusion printing use Made in Space’s 3DP Development ● Microgravity Flights in 2011, 400 parabolas or 2+ hours of microgravity. ● 28 hours of operation and 25 individual parts printed on the ISS. Next Generation Printer - Additive Manufacturing Facility ● EXPRESS Rack Payload designed for long term use

5 Since 2010, Made In Space has been the leaders of In-Space Manufacturing 6 3D Printing In Zero-G Experiment

The 1st 3D Printer in Space

7 3D Printing In Zero-G Experiment Results

Mission Success! ● Demonstrated 3D printing in microgravity to create ABS plastic items ● Completed full set of 21 parts and 4 calibration prints in just 3 weeks ● Demonstrated remote operation of 3D printing ● Demonstrated on-demand uplinking and printing of part (ratchet) ● Developed on-orbit operations for in space manufacturing ● Planning underway for more printing Technology developed and lessons learned were applied to our 2nd on-orbit 3D printing system: Manufacturing Device (also known as Additive Manufacturing Facility - AMF)

8 The first items 3D printed in space.

9 10 5 Main Technological Challenges: 1.Fluctuating Forces → Gravity Independence 2.Unreliable Prints → Mission Critical Engineering 3.Complex Interface → Remote Operations Design 4.Safety Requirements → Strict NASA Requirements 5.Toxic Gasses → Environmental Control Unit

11 12 Manufacturing Device 2nd Generation ISS 3D Printer

3D Printing Facility Aboard ISS Available to NASA, Educational, and Commercial Users

13 Manufacturing Device Overview

Manufacturing Device represents the compilation of all R&D efforts MIS has performed towards 3D printing in microgravity. Design based off of previous experience gained from 3D Print and almost 30 hours of printer operation on the ISS. Bigger, Better, Faster Key Specifications ● Extrusion based 3D printing technology ○ Suitable for a range of Polymers as well as Composite materials ● Designed to operate in an EXPRESS Rack MDL. ● Integrated printed part Verification system ● Replaceable Subassemblies ● Limited crew time needed to operate ● Remotely operable by ground ● Fully operable by the MIS ground crew

Launch and Integration in Increment 45/46. Print operations starting Increment 47 thru life of station. 14 Manufacturing Device Specifications:

Print Volume Spares and Consumables Up to 18 cm x 14 cm x 10 cm - 1 year supply of material - Quick swap components Materials ABS - Rigid and strong polymer material used on the 3D Printing in Zero-G experiment PEI/PC - Aerospace grade Engineering Plastic with low outgassing and flammability HDPE - Durable and flexible polymer

Resolution Down to 75 micron layer height

Print Features Thin walls down to 1mm Thru holes Threaded holes >M10 Overhangs up to 3 inches 15 Example Applications:

❏ 3D printing in microgravity science ❏ Support Experiments ❏ Consumables ❏ Replacement parts ❏ On-demand items ❏ Crew Tools ❏ Design iterations ❏ Satellites ❏ Hardware emergencies ❏ Many more..

16 Example Applications:

17 Example Parts, Tools, and Consumables:

18 What is the process for “emailing” an object space?

19 Manufacturing Device Concept of Operations:

MIS creates File uplinked to Customer supplied Test print on printable file Manufacturing design or specs Ground Unit configured for Device on ISS for Manufacturing printing Device

Print is When Crew Print initiated Crew replaces Monitored by complete, removes Tray by MIS Print Tray and MIS Ground system is from printer Ground Crew closes door. Crew cooled and and removes door opened. part from Tray

20 Concept of Operations Case Study:

21 22 23 24 25 26 27 28 29 End Use Options:

● Bagged and down massed for analysis ● Integrated into another payload ● Standalone payload ● Crew item or tool ● Launch from ISS (satellites)

30 How you can use the Manufacturing Device

● The Manufacturing Device is a commercial facility (MIS-owned) which will be used as a test-bed for Exploration needs.

● The utilization will be shared between commercial customers and NASA users.

● The NASA ISM team is working with MIS and MSFC procurement to develop a contract for NASA AMF Utilization. NASA users will work bring requests to the to NASA ISM team and ISM will consolidate the NASA utilization requests for submission to ISS. Get your items on the Print Queue! Contact us with your ideas

31 Discussion

Contact Info: Matthew Napoli Project Manager [email protected]

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