Abstract
In 2014, NASA, in partnership with Made In Space, Inc., launched the first 3D printer to the International Space Station (ISS). Results of the first phase of operations for this mission demonstrated the use of the fused filament fabrication (FFF) process for 3D printing in a microgravity environment. Previously published results indicated differences in density and mechanical properties of specimens printed in microgravity and those manufactured with the printer prior to its launch to ISS. Based on extensive analyses, these differences were hypothesized to be a result of subtle changes in manufacturing process settings rather than a microgravity influence on the FFF process. Phase II operations provided an opportunity to produce additional specimens in microgravity, evaluate the impact of changes in the extruder standoff distance, and ultimately provide a more rigorous assessment of microgravity effects through control of manufacturing process settings. Based on phase II results and a holistic consideration of phase I and phase II flight specimens, no engineering-significant microgravity effects on the process are noted. Results of accompanying material modeling efforts, which simulate the FFF process under a variety of conditions (including microgravity), are also presented. No significant microgravity effects on material outcomes are noted in the physics-based model of the FFF process. The 3D Printing in Zero G Technology Demonstration Mission represents the first instance of off-world manufacturing. It represents the first step toward transforming logistics for long-duration space exploration and is also an important crew safety enhancement for extended space missions where cargo resupply is not readily available. This paper presents the holistic results of phase I and II on-orbit operations and also includes material modeling efforts.
Similar content being viewed by others
References
Cirillo C, Goodliff K, Aaseng G, Stromgren C, Maxell A (2011) Supportability for beyond low earth orbit missions. Proceedings of the AIAA Space and Astronautics Forum and Exposition 2017. Long Beach, California
Owens A, de Weck O, Stromgren C et al (2017)Supportability challenges, metrics, and key decisions for human spaceflight. AIAA 2017–5124. Proceedings of the AIAA Space and Astronautics Forum and Exposition 2017. Orlando, FL
Owens A and DeWeck O (2016) Systems analysis of in-space manufacturing applications for the International Space Station and the Evolvable Mars Campaign, AIAA 2016–5394. Proceedings of the AIAA Space and Astronautics Forum and Exposition 2016. Long Beach California
Snyder M, Dunn J and Gonzalez E (2013) The effects of microgravity on extrusion based additive manufacturing. AIAA 2013-5439. Proceedings of the AIAA Space and Astronautics Forum and Exposition
Prater TJ, Bean QA, Beshears RD, et al (2016) Summary report on phase I results from the 3D Printing in Zero-G Technology Demonstration Mission, Volume 1. NASA Technical Publication —2016–219101. NASA Marshall Space Flight Center, Huntsville, AL, 156 pp
Prater T, Quincy B, Werkheiser N, and Ledbetter F (2016) NASA’s In-Space Manufacturing initiative: initial results from International Space Station Technology Demonstration and Future Plans. Proceedings of National Space and Missile Materials Symposium, Westminster Colorado
Prater TJ, Bean QA, Werkheiser N et al (2017) Analysis of specimens from phase I of the 3D Printing in Zero G Technology Demonstration Mission. Rapid Prototyp J 23(6):1212–1225
Prater T, Bean QA, Werkheiser N, et al (2017) A ground-based study on extruder standoff distance for the 3D Printing in Zero Gravity Technology Demonstration Mission. NASA Technical Publication —2017–219631. NASA Marshall Space Flight Center, Huntsville, AL, 94 pp
Prater TJ, Werkheiser N, Ledbetter F (2018) Summary report on phase I and phase II results from the 3D Printing in Zero-G Technology Demonstration Mission, Volume II. NASA Technical Publication
ASTM D638-14 (2014) Standard test method for tensile properties of plastics. ASTM International, West Conshohocken
ASTM D695-15 (2015) Standard test methods for compressive properties of rigid plastics. ASTM International, West Conshohocken
Ziemian C, Sharma M, and Ziemian S (2012) Chapter 7, Anisotropic mechanical properties of ABS parts fabricated by fused deposition modelling, in Mechanical engineering. Dr. Murat Gokcek (Ed.), InTech,cdn.intechopen.com/pdfs/35261/InTech-Anisotropic_mechanical_properties_of_abs_parts_fabricated_by_fused_deposition_modelling.pdf
Dinwiddie RB, Love LJ and Rowe RC (2013) Real-time process monitoring and temperature mapping of a 3D polymer printing process, Proc. SPIE 8705, Thermosense: thermal infrared applications XXXV, 87050L, G.R. Stockton and F.P. Colbert (Eds.)
Sun Q, Rizvi GM, Bellehumeur CT, Gu P (1995) Effect of processing conditions on the bonding quality of FDM polymer filaments. Rapid Prototyp J 14(2):72–80
Rodriguez JF, Thomas JP, Renaud JE (2001) Mechanical behavior of acrylonitrile-butadiene styrene (ABS) fused deposition materials: experimental investigation. Rapid Prototyp J 7(3):148–158
Additive Manufacturing Facility (AMF) user guide, Made In Space, <http://madeinspace.us/wp-content/uploads/AMF-User-Guide.pdf>, April 29, 2016
ABS material data sheet. TestStandard. http://www.teststandard.com/data_sheets/ABS_Data_sheet.pdf
Overview of materials for acrylonitrile butadiene styrene (ABS), extruded. MatWeb. http://www.matweb.com/search/DataSheet.aspx?MatGUID=3a8afcddac864d4b8f58d40570d2e5aa
Osswald T, Ortiz J (2006) Polymer processing modeling and simulation. Handser Gardner, Cincinnati, p 633
Rahman M, Schott N.R., and Kanta Sadhu L Glass Transition of ABS in 3D Printing. Excerpt from the Proceedings of the 2016 COMSOL Conference. Boston, MA. http://www.comsol.com/paper/download/361301/rahman_paper.pdf
ABS physical properties. A&C Plastics, Inc. http://www.acplasticsinc.com/media/documents/ABS_PP.pdf
McIlroy C, Olmsted PD (2017) Disentanglement effects on welding behaviour of polymer melts during the fused-filament-fabrication method for additive manufacturing. Polymer 123:376–391
ABS general purpose. MatBase. http://www.matbase.com/material-categories/natural-and-synthetic-polymers/thermoplastics/commodity-polymers/material-properties-of-acrylonitrile-butadiene-styrene-general-purpose-gp-abs.html#properties
ANSYS CFX-Solver theory guide. http://148.204.81.206/Ansys/150/ANSYS%20CFX-Solver%20Theory%20Guide.pdf
Chen R, Ramachandran A, Liu C, Chang F, et al. (2017) Tasi-Wu analysis of a thin-walled 3D-printed polylactic acid (PLA) structural bracket. AIAA 2017-0567. Proceedings of 58th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference. Grapevine, Texas
Guthrie P (2016) ‘Sporks in Space’: Bothell firm brings recycling to final frontier. Herald Business Journal, www.heraldnet.com/business/sporks-in-space-bothell-firm-brings-recycling-to-final-frontier/
Snyder R (2017) Reversible thermoset materials for in situ resource utilization. Proc. 2017 National Space and Missile Materials Symposium, Indian Wells, CA
CRISSP—Customizable Recyclable International Space Station Packaging, Abstract from NASA SBIR STTR database, <www.sbir.gov/sbirsearch/detail/1148879>, 2015
Prater T, Werkheiser N, and Ledbetter F (2017) Toward a multimaterial fabrication laboratory: In-Space Manufacturing as an enabling capability for long endurance human space flight. Proceedings of the AIAA Space and Astronautics Forum 2017, Orlando, FL
In-Space Manufacturing (ISM) Multi-material Fabrication Laboratory (FabLab), Broad Agency Announcement. <www.fbo.gov/index?s=opportunity&mode=form&tab=core&id=8a6ebb526d8bf8fb9c6361cb8b50c1f8&_cview=1>, Solicitation Number: NNHZCQ001K-ISM-FabLab, April 11, 2017
Warner C (2017) NASA selects three companies to develop ‘FabLab’ prototypes, NASA press release 17-094. www.nasa.gov/press-release/nas-selects-three-companies-to-develop-fablab-prototypes
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Prater, T., Werkheiser, N., Ledbetter, F. et al. 3D Printing in Zero G Technology Demonstration Mission: complete experimental results and summary of related material modeling efforts. Int J Adv Manuf Technol 101, 391–417 (2019). https://doi.org/10.1007/s00170-018-2827-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2827-7