3D printing Archives

October 19, 2024October 19, 2024 by Matt Williams

New Simulation Will Help Future Missions Collect Moon Dust

The ESA lunar base, showing its location within the Shackleton Crater at the lunar south pole. New research proposes building a repository at one of the lunar poles to safeguard Earth's biodiversity. Credit: SOM/ESA

In this decade and the next, multiple space agencies will send crewed missions to the Moon for the first time since the Apollo Era. These missions will culminate in the creation of permanent lunar infrastructure, including habitats, using local resources – aka. In-situ resource utilization (ISRU). This will include lunar regolith, which robots equipped with additive manufacturing (3D printing) will use to fashion building materials. These operations will leverage advances in teleoperation, where controllers on Earth will remotely operate robots on the lunar surface.

According to new research by scientists at the University of Bristol, the technology is one step closer to realization. Through a virtual simulation, the team completed a sample collection task and sent commands to a robot that mimicked the simulation’s actions in real life. Meanwhile, the team monitored the simulation without requiring live camera streams, which are subject to a communications lag on the Moon. This project effectively demonstrates that the team’s method is well-suited for teleoperations on the lunar surface.

September 18, 2024September 18, 2024 by Matt Williams

Metal Part 3D Printed in Space for the First Time

The ESA has created the first 3D-printed metal component in space. Credit: ESA/NASA

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!

June 26, 2024June 26, 2024 by Mark Thompson

Fly Through the Pillars of Creation in this New Visualisation Made from Webb and Hubble Data

Webb and Hubble images of the Pillars of Creation

I remember April 1995 very well. It was the month that the stunning and iconic image that has been called ‘Pillars of Creation’ was released. It was taken by the Hubble Space Telescope but now the James Webb Telescope is getting in on the act. Webb snapped images of the Eagle Nebula (home to the ‘pillars’) early on but now astronomers have combined the data form Hubble and Webb to create an amazing 3D animation flight through the nebula.

June 5, 2024June 5, 2024 by Mark Thompson

Metal is 3D Printed on the Space Station

I have always wanted a 3D printer but never quite found a good enough reason to get one. Seeing that NASA are now 3D printing metal is even more tantalising than a plastic 3D printer. However, thinking about it, surely it is just a computer controlled soldering iron! I’m sure it’s far more advanced than that! Turns out that the first print really wasn’t much to right home about, just an s-curve deposited onto a metal plate! It does however prove and demonstrate the principle that a laser can liquify stainless steel and then deposit it precisely in a weightless environment.

October 21, 2023October 21, 2023 by Matt Williams

NASA Tests a 3D Printed Aluminum Rocket Nozzle

The RAMFIRE nozzle performs a hot fire test at Marshall’s East test area stand 115. Credit: NASA

When it comes to the current era of space exploration, one of the most important trends is the way new technologies and processes are lowering the cost of sending crews and payloads to space. Beyond the commercial space sector and the development of retrievable and reusable rockets, space agencies are also finding new ways to make space more accessible and affordable. This includes NASA, which recently built and tested an aluminum rocket engine nozzle manufactured using their new Reactive Additive Manufacturing for the Fourth Industrial Revolution (RAMFIRE) process.

October 7, 2023October 7, 2023 by Nancy Atkinson

This Moon Rover Wheel Could be 3D Printed on the Moon

NASA mechanical design engineer Richard Hagen, left, and ORNL researcher Michael Borish inspect a lunar rover wheel prototype that was 3D printed at the Manufacturing Demonstration Facility. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

When you think about sending missions to the Moon, every single gram counts on launch day. Therefore, it makes sense to live off the land when you arrive with in-situ resource utilization. For example, what if you could fly a rover without wheels and 3D print them out of lunar regolith when you get there?

It just might happen.

Researchers used a 3D printer to build the same design for a wheel that will be part of the upcoming NASA VIPER rover. It was done using additive manufacturing (another word for 3D printing), melting metal powder and laying down and bonding a large number of successive thin layers of materials into the designed shape.

March 1, 2022March 1, 2022 by Andy Tomaswick

Future Astronauts Might be Able to 3D Print Their own Spacesuits and Parts as Needed

One of the best motivators to solve a problem is to experience it yourself. Dr. Bonnie Dunbar happened to have just such an experience. She is a former NASA astronaut and is now a professor of Aerospace Engineering at Texas A&M. While she was in the astronaut corps, she realized that some of her fellow astronauts couldn’t fit in an Extra Vehicular Activity suit – more commonly known as a spacesuit. So she decided not only to create one for the individuals with the original problem but to create a process by which any other astronaut launched on any future mission can have a spacesuit tailored to their own specific body. And now, her former employer (NASA) is funding her and her lab to complete a feasibility study of this customization process as part of the recently announced NASA Institute for Advanced Concepts (NIAC) program.

September 17, 2021September 17, 2021 by Andy Tomaswick

Astronaut Blood and Urine Could Help Build Structures on the Moon

Thinking outside the box has always been a strong suit of space exploration. Whether taking a picture of the Earth in a sunbeam or attempting to land a rocket on a floating ship, trying new things has been a continual theme for those interested in learning more about the universe. Now, a team from the University of Manchester has come up with an outside-the-box solution that could help solve the problem of building infrastructure in space – use astronauts themselves as bioreactors to create the building blocks of early colonies.

September 10, 2021September 10, 2021 by Andy Tomaswick

Astronomers Create 3D Printed Nebulae

Visualizations can inspire creative new ways of thinking about an object. But holding that visualization in your hand adds a whole other level of impact to it. That desire for impact has led Dr. Nia Imara, an astrophysicist and artist at UC Santa Cruz, to create the first-ever 3D printed models of stellar nurseries.

August 13, 2021August 13, 2021 by Andy Tomaswick

NASA Sends a 3D Printer for Lunar Regolith and More to the ISS

One of the reasons the ISS is still alive and kicking is that it offers a unique environment for testing that is available nowhere, either on the Earth or off of it. Plenty of science experiments want to take advantage of that uniqueness. This week, a fresh crop of experiments was delivered to the ISS aboard a Northrop Grumman Cygnus resupply craft. They range from 3D printers to a high school science experiment with mold, and now they each have the opportunity to make use of the ISS’s microgravity environment.