3D printing holds incredible promise for space exploration. Its speed and efficiency make it ideal for environments where resources are limited. However, the effects of microgravity on the 3D printing process remain largely unknown. To address this gap, the German Federal Institute for Materials Research and Testing (BAM), Clausthal University of Technology, and the German Aerospace Center (DLR) have launched a project called “Powder Additive Production under Weightless Conditions.†The goal is to study how microgravity affects 3D printing and to move us closer to a future where space-based manufacturing becomes routine.
As part of DLR’s 30th parabolic flight campaign, researchers conducted powder-based 3D printing experiments over five days. These flights were organized by the French company Novespace on behalf of DLR. The experiments took place aboard an Airbus A310 aircraft, which was equipped with a large onboard laboratory. The plane flew from Bordeaux across the Atlantic, completing 31 parabolic flights each day over four days. During each parabola, the crew experienced about 22 seconds of weightlessness, and after four days, they had accumulated 35 minutes of microgravity time.
NASA has already been using a 3D printer on the International Space Station, but that device uses a plastic-based FDM (Fused Deposition Modeling) system. The current project focuses on metal powder bed systems, which are more complex and require precise control in microgravity. Previously, it was challenging to maintain the stability of the powder bed without gravity to hold the material in place.
To overcome this, the team developed an air-gas flow inhalation system. This system uses vacuum pressure to keep the metal powder in position during the layer-by-layer printing process. The experiment successfully printed 30 layers of a test object, marking a significant milestone. Not only does this method stabilize the printing process in microgravity, but it could also improve 3D printing techniques on Earth. The findings suggest that this technology may help refine additive manufacturing in both space and terrestrial applications.
Langrui Energy (Shenzhen) Co.,Ltd , https://www.langruibattery.com