European Space Agency Develops High-temperature FFF 3D Printer For The International Space Station

On March 23, a consortium under the European Space Agency (ESA) designed and manufactured an early FFF 3D printer for the International Space Station (ISS). The prototype system is developed as part of the IMPERIAL project, which uses conveyor belt components to (theoretically) 3D print parts in unlimited length. At the ESA Advanced Manufacturing seminar in early March, the function of the unnamed 3D printer was demonstrated. The product can be compatible with all high-temperature engineering filaments. Participants witnessed the process of making 1.5m long steel bars on site.

The consortium of the project includes German aerospace companies OHB and Azimut Space, the Aslon Institute of Technology in the Republic of Ireland and the Portuguese 3D printer provider BEEVERYCREATIVE. "Through this activity, we overcame one of the main limitations of 3D printing - volume - and used a compact 3D printer capable of handling high-performance thermoplastics." Ugo Lafont, a material expert at ESA, explained. "This is a great achievement, and it will expand the application field of this on-demand manufacturing process."

The International Space Station

The International Space Station. The picture is from NASA.

What is the IMPERIAL project?

After ESA's initial MELT project was successful, the project tested the feasibility of industrial FFF 3D printing under microgravity conditions, and then launched the IMPERIAL project. Project IMPERIAL plans to take further action and develop a complete space manufacturing system that can overcome the size limitations of today's 3D printers. Therefore, the system will eventually be used for on-demand manufacturing and maintenance on the International Space Station, thus providing self-sufficient space for future long-term space flight.

Adventit Makaya, a senior manufacturing engineer at ESA, pointed out: "The development of an extraterrestrial manufacturing solution for large parts in an environment of human exploration (for example, here, and then on the structural parts of spacecraft) is critical to enhance sustainability and reliability. It is a powerful capability for future space flight missions."

Before the IMPERIAL project, ESA consortium developed a 3D printing system with microgravity function under the MELT project. The picture is from BEEVERYCREATIVE.

Space industrial FFF 3D printing

The printer itself must comply with many strict technical requirements. This includes being able to print high-performance engineering polymers such as PEEK, being able to print under microgravity conditions, while maintaining the quality of parts similar to the earth, and being able to print infinite large parts in one direction. The power consumption of the system is also strictly limited, and due to the lack of post-processing facilities in the space, it must be ready to use functional printed parts directly from the construction room. To ensure successful integration into ISS, the team was also forced to consider the availability of raw materials when designing 3D printers. Any scrap remaining after the production of parts shall be minimized at least, and can be completely reused when possible.

Antonella Sgambati, OHB project manager, added: "Facts have proved that FFF using high-performance polymer is not affected by gravity reduction environment, which paves the way for new challenges, such as printing unlimited length in one direction or using batch production. In the framework of this project, new technology gaps have been identified and remedied in the prototype development and testing of BEEVERYCREATIVE, thus achieving this unique achievement, making manufacturing processes outside the earth Another step forward. "

The new Project IMPERIAL 3D printer is used to produce 1.5m long steel bars

The new Project IMPERIAL 3D printer is used to produce 1.5m long steel bars. Photographed by ESA.

With the prospect of interplanetary space flight getting closer to reality, space additive manufacturing has become a hot topic in the aerospace field. Earlier this year, COSM Advanced Manufacturing Systems, an engineering company, began the final development and construction of metal EBM 3D printers for NASA. The system is designed to meet NASA's requirements for automated manufacturing and component maintenance in space. Starting from the Artemis program, the system will be used for the entire space, lunar and Mars missions.

Elsewhere, researchers at Brunswick University of Technology and the Hanover Laser Center (LZH) recently printed lunar heavy rocks in 3D under zero gravity for the first time. In the experimental "MOONRISE" project, the team installed a customized laser on its "MIRA3D" lunar rover and melted the lunar dust into a sphere, paving the way for manufacturing economic structures on the moon.