Additive manufacturing, also known as 3D printing, has had a profound impact on the way we do business. There is scarcely any industry that has not been affected by the adoption of this technology, and that includes spaceflight. Companies like SpaceX, Rocket Lab, Aerojet Rocketdyne, and Relativity Space have all turned to 3D printing to manufacture engines, components, and entire rockets. NASA has also 3D-printed an aluminum thrust chamber for a rocket engine and an aluminum rocket nozzle, while the ESA fashioned a 3D-printed steel floor prototype for a future Lunar Habitat.
Similarly, the ESA and NASA have been experimenting with 3D printing in space, known as in-space manufacturing (ISM). Recently, the ESA achieved a major milestone when their Metal 3D Printer aboard the International Space Station (ISS) produced the first metal part ever created in space. This technology is poised to revolutionize operations in Low-Earth Orbit (LEO) by ensuring that replacement parts can be manufactured in situ rather than relying on resupply missions. This process will reduce operational costs and enable long-duration missions to the Moon, Mars, and beyond!
The Metal 3D Printer is a technology demonstrator built by an industrial team led by Airbus Defence and Space (SAS) in partnership with the ESA’s Directorate of Human and Robotic Exploration. It was launched to the ISS in late January and installed in the European Drawer Rack aboard the ESA’s Columbus Laboratory Module by European astronaut Andreas Mogensen. The printer became operational by the following June, and the first 3D metal shape was produced by August. With the first metal component built, the ESA plans to create three more as part of the experiment.
These four samples will then be sent to Earth for quality analysis and testing. Two will be sent to the ESA’s European Space Research and Technology Centre (ESTEC) in the Netherlands, a third to the Technical University of Denmark (DTU), and the fourth to the ESA’s European Astronaut Centre (EAC) in Cologne, where it will be integrated into the LUNA facility—a lunar analog environment designed for astronaut training. The availability of ISM will significantly reduce the challenges of resupplying spacecraft as they travel to the Moon, Mars, and other locations in deep space.
For long-duration missions on the lunar surface, the ability to print machine parts and ship them directly from LEO will reduce the number of launches needed to sustain operations there. As for Mars, the ability to manufacture replacement parts, repair equipment, and construct specific tools on demand will ensure a measure of autonomy for mission crews and reduce their reliance on resupply missions sent from Earth. This is especially important given the limited launch windows to Mars (every 26 months) and the time it takes to make a one-way transit (6 to 9 months).
NASA is also pursuing an ISM project aboard the ISS with the help of its commercial partners through the Marshall Space Flight Center (MSFC), with additional support provided by the physics-based modeling group at NASA’s Ames Research Center. These efforts began in 2014 when NASA launched the first 3D printer (manufactured by Made In Space, Inc.) to the ISS. This technology demonstrator used the fused filament fabrication (FFF) process to create objects out of plastic and proved that 3D printing could work in a microgravity environment.
This was followed by the creation of the Additive Manufacturing Facility (AMF), which can print using a variety of materials. These devices allowed for the creation of the first 3D-printed tools in space, including a plastic wrench, a rachet wrench, and more. In 2019, NASA added the ReFabricator experiment to the ISS, which was developed by Tethers Unlimited to create 3D-printed parts using recycled plastic materials. However, the ESA’s technology demonstrator is the first to successfully print a metal component in microgravity conditions.
The experiments will not stop there. In 2021, NASA sent another 3D printer to the ISS, the Redwire Regolith Print (RRP), designed to fashion construction materials out of lunar regolith. They are also investigating how Moon rover wheels can be 3D-printed on the lunar surface and how Martian rocks and minerals could be used to manufacture whatever future missions will need in situ. In collaboration with the University of Texas at El Paso (UTEP) and Youngstown State University (YSU), NASA is also considering how batteries could be 3D printed using lunar or Martian resources.
The potential applications for this technology are almost limitless and are integral to all plans for human expansion beyond Low Earth Orbit (LEO).
Further Reading: ESA