As it turns out, 3D printing techniques are perfect for use in space. Printers have become small, compact, fast, and powerful. And, as we've discussed before, a wider array of engineering materials are now available.
Packing for a working trip to the International Space Station, the moon, or Mars must be a lot harder than packing for a business trip to Europe. If all an astronaut needed to take along was a 3D printer with the right software library of tools and spare parts (plus some raw materials), that would make things a lot simpler, and it would probably cut fuel costs by a lot.
But additive manufacturing isn't just for astronauts. The makers of components for fighter jets, commercial planes, and unmanned aerial vehicles are also researching the use of 3D printers to produce end-use and production plastic and metal parts.
Many techniques are being put into play, including various forms of selective laser sintering (SLS), conformal lattice structures combined with SLS, fused deposition modeling, and NASA's electron beam freeform fabrication. One process, done with the Contour Crafting robot, can manufacture structures as large as apartment buildings and hotels using locally available materials such as clay and plaster.
Click the image below for 10 out-of-this-world examples of 3D printing techniques.
NASA-funded research by University of Southern California professors Behrokh Khoshnevis, Madhu Thangavelu, Neil Leach, and Anders Carlson is exploring how structures on the moon can made using the Contour Crafting robot. Under NASA's Innovative Advanced Concepts program, the researchers aim to develop methods for creating infrastructure, such as roads and landing pads, to support human settlement on the moon. The technology can create structures in situ from local materials, which is especially important for long-term, continuously expanding operations on the moon. For example, the team is exploring a nozzle system that heats lunar soil into a cement-like paste. In this visualization by Behnaz Farahi and Connor Wingfield, a lander descends on a pad fabricated by the Contour Crafting robot. (Source: University of Southern California/Contour Crafting)
Beth, the Mars project--even if only built on the ground during testing--should give some good data for the intended use of the technology, which the website states is emergency and low-cost shelters and/or permanent housing, ads well as commercial buildings. It will be interesting to see the results.
The idea of being able to 3D print whole buildings is definitely something that could have huge impact on housing the developing world or even providing respite after disasters like the Japanese earthquake and tsunami and the earthquake in Haiti. I would think it's a fast, reasonably inexpensive way to get shelter up and usable quickly. I hope that this actually can become a reality because the possibilities are pretty unbelievable.
Jim, thanks for that experimental info. I've read elsewhere that one big inhibitor to date for using AM techniques in aerospace is the lack of resistance of the materials to temperature extremes, especially high temps. OTOH, high-end AM materials are not just for making prototypes anymore--they're increasingly used for low-end aerospace production components, as we've covered here http://www.designnews.com/document.asp?doc_id=236261 But since Stratasys' FDM is being used on test parts for Mars rovers, NASA must believe it's possible to overcome those limitations. Also, other materials have worked successfully on non-interior aircraft parts, usually processed with various forms of SLS.
To me, the most amazing thing is that this technology could be used to build "infrastructure, such as roads and landing pads." It's one thing to build components that have to handl light mechanical stresses. It's another to build structural components that have to handle big loads.
As the 3D printing and overall additive manufacturing ecosystem grows, standards and guidelines from standards bodies and government organizations are increasing. Multiple players with multiple needs are also driving the role of 3DP and AM as enabling technologies for distributed manufacturing.
A growing though not-so-obvious role for 3D printing, 4D printing, and overall additive manufacturing is their use in fabricating new materials and enabling new or improved manufacturing and assembly processes. Individual engineers, OEMs, university labs, and others are reinventing the technology to suit their own needs.
For vehicles to meet the 2025 Corporate Average Fuel Economy (CAFE) standards, three things must happen: customers must look beyond the data sheet and engage materials supplier earlier, and new integrated multi-materials are needed to make step-change improvements.
3D printing, 4D printing, and various types of additive manufacturing (AM) will get even bigger in 2015. We're not talking about consumer use, which gets most of the attention, but processes and technologies that will affect how design engineers design products and how manufacturing engineers make them. For now, the biggest industries are still aerospace and medical, while automotive and architecture continue to grow.
More and more -- that's what we'll see from plastics and composites in 2015, more types of plastics and more ways they can be used. Two of the fastest-growing uses will be automotive parts, plus medical implants and devices. New types of plastics will include biodegradable materials, plastics that can be easily recycled, and some that do both.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.