An Overview of NASA’s In-Space Manufacturing (ISM) Project

Niki WerkheiserManager, NASA In-Space Manufacturing (ISM)

256-544-8406 [email protected]

An Overview of NASA’s In-Space Manufacturing (ISM) Project

February 21, 2018

ISM works with Exploration designers to optimize parts/systems for on-orbit

maintainability & repair

ISMPrimaryFocusAreas

vIn-SpaceManufacturing&Repair:Workwithindustryandacademiatodevelopon-demandmanufacturingandrepairtechnologiesforin-spaceapplications.

• TwopolymerprinterscurrentlyonISS(3DPrintTechDemo&AMF).SupportingSTMDTDMArchinaut(MIS)TippingPointforExternalISM.

• NextSTEPPhaseABroadAgencyAnnouncement(BAA)forthe1st GenerationMulti-Material“FabLab”Demonstrationcapableofmetallicmanufacturingin-space.

vIn-SpaceManufacturingDesignDatabase(i.e.WHATweneedtomake):ISMisworkingwithExplorationSystemDesignerstodeveloptheISMdatabaseofparts/systemstobemanufacturedonspaceflightmissions.

• Includesmaterial,verification,anddesigndata.• Ultimately,thiswillresultinanISMUtilizationCatalog

ofapprovedpartsforon-orbituse.

vIn-SpaceRecycling&Reuse:WorkwithIndustryandacademiatodeveloprecycling&reusecapabilitiestoincreasemissionsustainability.

• TheRefabricator(integrated3DPrinter/Recycler)TechDemolaunchingtoISSinearly2018.

• ERASMUSPhaseIISBIRwithTUIdevelopingFood&MedicalGradeRecyclingCapability.

• CommonUseMaterialsPhaseIISBIRs(TUI&CRG).

Multi—material ‘FabLab’ BAA will result in 1st Gen Exploration System

ISS Refabricator developed via SBIRs with Tethers Unlimited, Inc.

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In-SpaceManufacturing(ISM)Portfolio

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IN-SPACERECYCLING

IN-SPACEV&V

PROCESS

• ISS On-demand Mfg. w/polymers

• 3DP Tech Demo• Additive

Manufacturing Facility with Made in Space, Inc. (MIS)

• Material Characterization & Testing

• Develop Multi-Material Fabrication Laboratory Rack as ‘springboard’ for Exploration missions

• In-Space Metals ISS Tech Demo

• nScrypt Multi-Material machine at MSFC for R&D

MULTI-MATERIALFABLABRACK

PRINTEDELECTRONICS

IN-SPACEPOLYMERS

EXPLORATIONDESIGN

DATABASE&TESTING

• RefabricatorISS Tech Demo with Tethers Unlimited, Inc. (TUI) for on-orbit 3D Printing & Recycling

• Multiple SBIRs underway on common-use materials & medical/food grade recycler

MSFC Conductive & Dielectric Inks patented• Designed &

Tested RFID Antenna, Tags and Ultra-capacitors

• 2017 ISM SBIR subtopic

• Collaboration w/ARC on plasma jet technology

• Develop design-level database for micro-g applications

• Includes materials characterization database in MAPTIS

• Design & test high-value components for ISS & Exploration (ground & ISS)

• Develop & Baseline on-orbit, in-process certification process based upon the DRAFT Engineering and Quality Standards for Additively Manufactured Space Flight Hardware 32

ISMCapabilitiesPortfolio

ISSservesasaKeyExplorationTest-bedfortheRequiredISMTechnologyMaturation&Demonstrations

ISMISMExplorationCapabilityRoadmap

Pre-2012

• ISS 3DP Tech Demo: First Plastic Printer on ISS

• NIAC Contour Crafting

• NIAC Printable Spacecraft

• Small Sat in a Day

• AF/NASA Space-based Additive NRC Study

• ISRU Phase II SBIRs

• Ionic Liquids• Printable

Electronics

• 3DPTechDemo• Add.Mfctr.Facility(AMF)

• ISMCertificationProcessPartCatalog

• ISS&ExplorationMaterial&DesignDatabase

• ExternalManufacturing

• AutonomousProcesses

• STEM(FutureEngs.)

• AdditiveConstruction

Cislunar, Lagrange FabLabs• Initial

Robotic/Remote Missions

• Provision feedstock

• Evolve to utilizing in-situ materials (natural resources, synthetic biology)

• Product: Ability to produce, repair, and recycle parts & structures on demand; i.e.. “living off the land”

• Autonomous final milling

Mars Multi-Material FabLab• Provision & Utilize

in situ resources for feedstock

• FabLab:Provideson-demandmanufacturingofstructures,electronics&partsutilizingin-situandexsitu(renewable)resources.Includesabilitytoinspect,recycle/reclaim,andpost-processasneededautonomouslytoultimatelyprovideself-sustainment at remote destinations.

Planetary Surfaces Points FabLab• Transport

vehicle and sites require FabLab capability (adapt for in-situ resource utilization)

• Additive Construction & Repair of large structures

Ground & Parabolic centric:• Multiple FDM

Zero-G parabolic flights

• Trade/System Studies for Metals

• Ground-based Printable Electronics/ Spacecraft

• Verification & Certification Processes under development

• Materials Database

• CubeSat Design & Development

LagrangePoint

CislunarMars

Asteroids

2014 2018 - 2024 2025 - 2035+

3D Print Plastic Printing

Demo

Polymer Mfctr. &

Recycling

Polymer Mfctr.

FabLab (Metals, Electronics)

ExternalMfg.

Ground&ISSDevelopment&Demonstration ExplorationImplementation

Additive Construction

Material Characterization

ISS:Multi-MaterialFabLabRackTestBed(KeyspringboardforExploration‘provingground’)• IntegratedFacilitySystemsforstrongertypesofextrusionmaterialsformultipleusesincludingmetals&variousplastics,embeddedelectronics,autonomousinspection&partremoval,etc.

• In-SpaceRecyclerTechDemo

• ACMEGroundDemos

Mat. Char. &

Dev.

2015-2017

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TheFirstStep:The3DPrintinginZeroGTechnologyDemonstrationMission(Ph.IIISBIRwithMadeinSpace,Inc.

The3DPinZeroGtechdemodeliveredthefirst3DprinterontheISSandinvestigatedtheeffectsofconsistentmicrogravityonfuseddepositionmodelingbyprinting55specimenstodateinspace.

Fused deposition modeling: 1) nozzle ejecting molten

plastic, 2) deposited material

(modeled part), 3) controlled movable table

ISS 3D Print Tech Demo SpecificationsDimensions 33 cm x 30 cm x 36 cmPrint Volume 6 cm x 12 cm x 6 cmMass 20 kg (w/out packing

material or spares)Power 176 WFeedstock ABS Plastic

PrinterinsideMicrogravityScienceGlovebox (MSG)

• PhaseIprints(Nov-Dec2014)consistedofmostlymechanicaltestcouponsaswellassomefunctionaltools

• PhaseIIspecimens(June-July2016)providedadditionalmechanicaltestcouponstoimprovestatisticalsampling

ISMFocalArea:In-SpaceManufacturingManufacturing&Repair

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And then…Additive Manufacturing Facility (AMF)(Ph. I, II, II-E SBIRs, NASA IDIQ with Made in Space, Inc.)

• Thesecond3DPrinter,theAdditiveManufacturingFacility(AMF),isnowoperatingonISS.

• ThisprinterisownedandoperatedbyMadeinSpace,Inc.thruagreementwiththeISSNationalLabandCenterforAdvancementofScienceinSpace(CASIS).

• NASAisoneofthecustomers,aswellasothergovernmentagencies,industry,andacademia.

• AMFcanprintwithABS,UltemandHigh-densityPolyethylene.


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• TethersUnlimitedMAMBA(MetalAdvancedManufacturingBot-AssistedAssembly)PhaseISBIR:

• Ingot-formingmethodtoprocessvirginorscrapmetal

• BulkfeedstockisCNC-milled• Buildsonrecyclingprocessdeveloped

throughRefabricatorpayload

• Techshot,Inc.SIMPLE(SinteredInductiveMetalPrinterwithLaserExposure)PhaseIISBIR:

• AMprocesswithmetalwirefeedstock,inductiveheating,andalow-poweredlaser

• Compatiblewithferromagneticmaterialscurrently

• TestunitforSIMPLEdevelopedunderphaseISBIR;phaseIIseekstodevelopprototypeflightunit

In-SpaceMetalManufacturingCapability-SBIRDevelopment

Techshot’s SIMPLE,asmallmetalprinterdevelopedunderaPhaseI

SBIR.

TethersUnlimitedMAMBA

• MadeinSpaceVulcanunit(PhaseISBIR):IntegratesFDMheadderivedfromtheadditivemanufacturingfacility(AMF),wireandarcmetaldepositionsystem,andaCNCend-millforpartfinishing

• UltraTechUltrasonicAdditiveManufacturing(UAM)system(PhaseISBIR)

• UAMprintspartsbyusingsoundwavestoconsolidatelayersofmetaldrawnfromfoilfeedstock(similartoultrasonicwelding)

• Solidstateprocessthatavoidscomplexitiesofmanagementofpowderfeedstock

• WorkistoreducetheUAMprocess’sfootprintbydesigningandimplementingahigherfrequencysonotrode

• Scalingofsystemalsohasimplicationsforroboticsandfreeformfabrication

IllustrationofUAMprocessunderaPh.ISBIR


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TheNextSTEPMulti-materialFabricationLaboratory(“FabLab”)BroadAgencyAnnouncement(BAA)

OverviewISMFocalArea:In-SpaceManufacturingManufacturing&Repair

PhaseA(18months)Goal:Demonstrateascalableground-basedPROTOTYPEofanISMFabLab System abletomatureintoflightdemonstrationsontheISSwithinthreeyears.

DESIGN

PhaseB(12months)Goal:MaturethePhaseAISMFabLab Systemprototypeintoapre-flightdeliverable. PhaseBcriteriaandneededpathareinformedbyPhaseAresultsandwillbereleasedunderafollow-onBAA.

BUILD

PhaseC(18months)Goal:DemonstratethecapabilityofaPhaseBISMFabLab SystemontheISSandevaluaterisk.PhaseCcriteriaareinformedbyPhaseBresultsandwillbereleasedasafollow-onBAAorotheracquisitionvehicle.

FLY

WEAREHERE!

● NASAsolicitedproposalsforthedevelopmentofamulti-materialfabricationlaboratory(FabLab)capableofend-to-endmanufacturingduringspacemissions.

● Thisisthefirststeptowardafully-integrated,on-demandmanufacturingcapabilitythatisabletoproducefinished,ready-to-useproductsduringExploration missions.

● NASA’sstrategyistoimplementaphasedapproachofincrementally-increasingcapabilitiestowardenablingExplorationofcislunarspaceandbeyond.

● ThePhaseBsolicitationwillbeopenlycompetedandisanticipatedtobereleasedlateinCY2019.

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”TheTechshot FabLab”-Techshot,Inc.(Greenville,IN)Partners:Sciperio,GEGlobal

Systems,UniversityofLouisville,WalterReedArmyMedicalCenter,Uniformed

ServicesUniversity

NextSTEP“FabLab”PhaseASelectees

“MicrogravityMultipleMaterialsAdditiveManufacturing(M3AM)Technology”- Interlog (Anaheim,CA)

Partners:ArgonneNationalLabs,MicroAerospaceSolutions

NASA12/7/17SelectionAnnouncement:https://www.nasa.gov/press-release/nasa-selects-three-companies-to-develop-fablab-prototypes

“Empyrean- Sustainable,In-SpaceFabricationLaboratoryforMultipleMaterialManufacturing,Handling,

andVerification/Validation”- TethersUnlimited,Inc.(Bothell,WA)

Partners:Stratasys,UniversityofTexasElPaso(UTEP),BluHaptics,Vader

Systems,IERUS.

• CombinedfundingforthePhaseAAwardsisapproximately$10.2million

• Thesecompanieswillhave18monthstodelivertheprototype,afterwhichNASAwillselectpartnerstofurthermaturethetechnologies.


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ISMPrintableElectronicsDevelopment(MultipleSBIRs)

• Evaluatingtechnologiestoenablemulti-material,on-demanddigitalmanufacturingofcomponentsforsustainableexplorationmissions

• PhaseISBIRs:Workonminiaturizationandadaptationofprintableelectronicsformicrogravityenvironment:o Techshot,Inc.(STEPS– SoftwareandToolsforElectronics

PrintinginSpace):DirectwriteandavionicsprintingcapabilityforISS

o Optomec workingonminiaturizationofpatentedAerosolJettechnology

o 2018SBIRCallforPlasmaJetPrintingforIn-SpaceManufacturingsubtopic

• In-housework:o nScryptprinter:4headsfordispensationofinksandFDMof

polymers;alsohaspickandplacecapabilityo Developedanddemonstratedthefunctionalityofapassive

wirelesshumiditysensorintendedforthein-linemonitoringofsystems.

o ECLSSandISMareplanningtoperformgrounddevelopmenttestingofsensorsintheECLSSenvironmentwhichintroducethepresenceofCO,CH4,andH2

o InitialdesignconceptofthefirstprintableECLSSpressureswitcho TriboelectricNanogenerator (TENG)forPowerGeneration:The

ARCteamdesignedandtestedpowergeneratorsforsmallscalepowergeneration.TheteamalsobuiltasmallMarsanalogueweatherchamberfordemonstratingthatMartianambientisfavorableforthisapproach.

PrintedWirelessHumiditySensor

MartianAnalogueWeather

Chamber(top)withLED’sdirectly

poweredbyTENG(bottom)inthechamber

PrintableECLSS

Pressureswitch


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MissionGoalofRefabricatorDemonstratetherepeatable,closed-loopprocessofrecyclingplasticmaterialsinthemicrogravity environmentoftheInternationalSpaceStation(ISS)intofeedstock forfabricationofnew/differentparts.

In-SpaceRecycling&Reuse:ISSRefabricatorDemonstration(SBIRI,II,II-E,IIIwithTethersUnlimited,Inc.)

ISMFocalArea:In-SpaceRecyclingandReuse

• TechnologyDemonstrationMissionpayloadconductedunderaSBIRwithTethersUnlimited,Inc.(TUI)

• Refabricatorisanintegrated3Dprinter(FDM)whichrecyclesplasticintofilamentfeedstockthroughanovelTUIprocesscoined,“Positrusion”.

• Designedtobeself-containedandhighlyautomated.

• HardwareturnoverforlaunchonISSinSummer2018.

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• TethersCRISSP(CustomizableRecyclableISSPackaging)seekstodevelopcommonusematerials(whicharedesignedtoberecycledandrepurposed)forlaunchpackagingo WorkunderphaseIISBIRo Recyclablefoampackagingmadefromthermoplasticmaterials

usingFDMo Cancreatecustominfillprofilesforthefoamtoyieldspecific

vibrationcharacteristicsormechanicalproperties

• CornerstoneResearchGroup(CRG)isworkingunderaphaseIISBIRondevelopmentofreversiblecopolymermaterialso Reversiblecopolymeractsasathermallyactivatedviscosity

modifierimpactingthemeltpropertiesofthematerialo Designshavestrengthandmodulusvaluescomparabletoor

exceedingbasethermoplasticmaterialswhilemaintainingdepressedviscositythatmakesthemcompatiblewithFDM

CRISSP(imagefromTethersUnlimited)

FDMprintsusingreclaimedanti-staticbaggingfilmwithreversiblecross-linkingadditive(imagefromCornerstoneResearchGroup)


In-SpaceRecycling&Reuse:CommonUseMaterials(MultiplePh.I&IISBIRs)

Logisticsanalysesshowthedramaticimpactofarecyclingcapabilityforreducinginitiallaunchmassrequirementsforlongdurationmissions.CurrentpackagingmaterialsforISSrepresentabroadspectrumofpolymers:LDPE,HDPE,PET,

Nylon,PVC.

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• CollaborationwiththeLRteamandTethersUnlimited,Inc.(TUI)viatheERASMUSPhaseIISBIRtodemonstratetheon-demandmanufacturing,recycling,andsanitizingofanLRUrineFunnel.

• TUIdigitallyreconstructedtheNASA-providedurinefunneldrawingandmadeadaptationsinordertobettersupportitsmanufacturability.Twovisualpropertiesoftheurinefunnelweredesignedforsmoothnessandopticalclarity.

ERASMUS(TUIPhaseIISBIR)- On-DemandManufacturing,Recycling&SanitizingforFoodandMedicalGradeParts

• TUIprovidedthreetypesofUrineFunnelspecimensoutofFoodsafe PLA(0.02mm,0.05mm,and0.25mmlayerheight)andoneprototypeoutofTaulman 680Nylon(0.20mmlayerheight).

FourPrintedUrineFunnels

• TheprototypesarrivedatMSFCinAugust2017andwasprovidedtotheJSCLogisticsReductionteamforfurthertestingandanalyses.

• InadditiontotheUrineFunnel,theERASMUSPhaseIISBIRactivityaddressesfood(i.e.spoon)andmedical(i.e.otoscopespecula)gradestudiesandspecimenproductionaswell.


In-SpaceRecycling&Reuse:ErasmusFood&MedicalGradeRecycler/Printer(Ph.I,IISBIRwithTUI)

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AdditiveManufacturingFacility(AMF)FunctionalPartsmadeonISS(NASAIDIQwithMadeinSpace,Inc.

• AdditiveManufacturingFacility(AMF)isthefollow-onprinterdevelopedbyMadeinSpace,Inc.

• AMFisacommercial,multi-userfacilitycapableofprintingABS,ULTEM,andHDPE.

• Todate,NASAhasprintedseveralfunctionalpartsforISSusingAMF

TheMadeinSpaceAdditiveManufacturingFacility(AMF)

SPHERESTowHitch:SPHERESconsistsof3free-flyingsatelliteson-boardISS.TowhitchjoinstwooftheSPHERESsatellitestogetherduringflight.Printed2/21/17.

REMShieldEnclosure:EnclosureforradiationmonitorsinsideBigelowExpandableActivityModule(BEAM).Printed3/20/17(1of3).Othersprinted5-30and6-16.AllarenowinstalledonBEAM.

AntennaFeedHorn:collaboration between NASA Chief Scientist & Chief Technologist for Space Communications and Navigation, ISM & Sciperio, Inc. Printed 3/9/17 and returned on SpaceX-10 3/20/17.

OGSAdapter:adapterattachesovertheOGSairoutletandfixturesthevelocicalc probeintheoptimallocationtoobtainaconsistentandaccuratereadingofairflowthroughtheport.7/19/2016.

ISMFocalArea:In-SpaceManufacturingDesignDatabase(i.e.WHATwemake)

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Crewswillfaceuniquehealthcarechallengesduringlongdurationspaceflightmissions.ISMisinvestigatingthewaysthaton-demandmanufacturingcan

assistwithnominalmedicalneeds,aswellasemergencyscenarios.

OtoscopeSpecula‘Reverse

Engineered’forCrewMedical

Office(JSC)


Areas ofInterest ExamplesMedicalTools Forceps,syringes,clamps,calipers,integratedwoundcareSterileMfctr.&

RecycleTUI ERASMUS PhaseIISBIR

SurgicalAids Customizedtrainingaids,jigs/guidestoaidinsurgery,3Dmodels

DentalCrowns,abutments,bridges,drillguides,aligners,biteguards,customscans; Terrestrialdentalindustryearlyadoptersofthesetechnologiesandprocesses.

Orthotics Customizedflexiblesplints,braces,casts,footinsertsAuditory

ImplementsCustomizedotoscopespecula,earprotection,hearingdevices,acousticmonitorcomponents

VisionImplements

Customizedcontactlenses,glasses(lensesandframes), diagnostics

CrewPersonal UrineFunnels(FY17);customizedexercise accessories,groomingtools,footcare,etc.

CustomPharmaceuticals

Customizedantibiotics,vitaminsandsupplements,etc.

Bioprinting MeatProducts,Skin-graftsforBurnCare

DiagnosticTools StructuredLightScannersforcomparativeparametricdatathroughoutmission

ISMVanderbiltSeniorDesignProject

ISMDesignDatabase:CrewHealthandSafetyApplications

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ü ThenScryptmulti-materialprinterisbeingutilizedtodesignandtestmulti-materialpartsandcomponents,suchasthoseforPrintableElectronics,ECLSS,LogisticsReduction,etc.ThiseffortalsobetterinformstheFabLabdevelopment.ThenScryptCapabilityDevelopmentPlanwasdevelopedandhasresultedincompletedprintparameteroptimizationforULTEM,aswellastensileresultswhicharecomparabletopropertiesforULTEMreportedontheStratasys printerspecificationsheet.


ISMDesignDatabase:Consumables

ü Demonstratedin-housecapabilitytoreplicatesparesandconsumablesforthenScryptprinterwhichresultedincostandschedulegains.

ü nScryptCeramicTip:• COTS:$260/each• In-house(MSFC):

~$0.25/eachü nScryptSmartPumpvalve

body:• COTS:$2500• In-house(MSFC):~$4.00

(forplasticresinforaconsumableversionoftheSmartPumpvalvebody)

COTSAssembly• Machinedvalve

body,aluminatip,andtipholder

• Expensiveandtimeconsumingtoclean

• Inhibitsfastmulti-materialprintingprocesses.

In-HousePrintedConsumablesandSpareparts

• PrintedValveBody,individualtipsandintegratedholder,andsyringe

• Savesthousandsofdollars• Enablesefficientmulti-

materialprinting

ComparisonofCOTS

AssemblytoIn-houseAssembly

COTS

In-house

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In-SpaceManufacturingSummary

• In-space Manufacturing offers:o Dramatic paradigm shift in the development and creation of space

architectureso Efficiency gain and risk reduction for deep space explorationo “Pioneering” approach to maintenance, repair, and logistics will lead to

sustainable, affordable supply chain model.• In order to develop application-based capabilities for Exploration, ISM

must leverage the significant and rapidly-evolving terrestrial technologies for on-demand manufacturing . o Requires innovative, agile collaboration with industry and academia. o NASA-unique Investments to focus primarily on developing the skillsets

and processes required and adapting the technologies to the microgravity environment & operations.

• Ultimately, an integrated “FabLab” facility with the capability to manufacture multi-material components (including metals and electronics), as well as automation of part inspection and removal will be necessary for sustainable Exploration opportunities.

NASA’s In-Space Manufacturing (ISM) Objective: Develop and test on-demand, manufacturing capabilities for fabrication, repair, and recycling during

Exploration missions.

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In-SpaceQuestions&Discussion

“Ifwhatyou’redoingisnotseenbysomepeopleassciencefiction,it’sprobablynottransformativeenough.”-SergeyBrin

Documents

An Overview of NASA’s In-Space Manufacturing (ISM) Project