Metal 3D printing will soon take place in orbit for the first time. A pioneering European-made metal 3D printer is on its way to the International Space Station on the Cygnus NG-20 resupply mission which launched on the 31st January.
ESA technical officer Rob Postema stated, “This new 3D printer printing metal parts represents a world first, at a time of growing interest in in-space manufacturing. Polymer-based 3D printers have already been launched to, and used aboard the ISS, using plastic material that is heated at the printer’s head, then deposited to build up the desired object, one layer at a time.”
“Metal 3D printing represents a greater technical challenge, involving much higher temperatures and metal being melted using a laser. With this, the safety of the crew and the Station itself have to be ensured – while maintenance possibilities are also very limited. If successful though, the strength, conductivity and rigidity of metal would take the potential of in-space 3D printing to new heights.”
Once arrived at the International Space Station, ESA astronaut Andreas Mogensen will prepare and install the approximately 180 kg Metal 3D printer in the European Draw Rack Mark II in ESA’s Columbus module. After installation, the printer will be controlled and monitored from Earth, so the printing can take place without Andreas’s oversight.
The Metal 3D Printer technology demonstrator has been developed by an industrial team led by Airbus Defence and Space SAS.
Project manager at Airbus, Patrick Crescence stated, “This in-orbit demonstration is the result of close collaboration between ESA and Airbus’ small, dynamic team of engineers.”
“But this is not just a step into the future; it’s a leap for innovation in space exploration. It paves the way for manufacturing more complex metallic structures in space. That is a key asset for securing exploration of Moon and Mars.”
The printer will be printing using a type of stainless-steel commonly used in medical implants and water treatment due to its good resistance to corrosion.
Four interesting shapes have been chosen to test the performance of the Metal 3D printer. These first objects will be compared to the same shapes printed on ground, called reference prints, to see how the space environment affects the printing process.
The four prints are all smaller than a soda can in size, weigh less than 250 g per print, and takes about two to four weeks to print. The scheduled print time is limited to four hours daily, due to noise regulations on the Space Station – the printer’s fans and motor of the printer are relatively noisy.
One of ESA’s goals for future development is to create a circular space economy and recycle materials in orbit to allow for a better use of resources. One way would be to repurpose bits from old satellites into new tools or structures. The 3D printer would eliminate the need to send a tool up with a rocket and allow the astronauts to print the needed parts in orbit
Thomas Rohr, overseeing ESA’s materials and processes section, stated, “This technology demonstration, showcasing the processing of metallic materials in microgravity, paves the way for future endeavours to manufacture infrastructure beyond the confines of Earth.”