"Revolutionizing Space: The Impact of 3D Printing in the Aerospace Sector" Part 1

Matthew Zaino
Oct 8, 2023
2 min read

Updated: Oct 11, 2023

By: Matt. Z

10/9/23

Part One of a Three part series.

With the first components orbiting about Earth in November of 1998. To its completion in May of 2009, the International Space Station (ISS) has served as a continuous residence for astronauts, providing a sanctuary of constant scientific discovery, with the station's primary objective for scientific research. It offers other essential amenities like dining, sleeping, relaxation, and exercise. The continuous maintenance of the station involves shipping over 7,000 pounds of spare parts annually, with an additional 29,000 pounds of hardware spares aboard and 39,000 pounds on Earth.

While this system suits the ISS's near-Earth orbit, it's impractical for missions to the Moon and Mars. Astronauts on extended journeys require the ability to manufacture spare parts and tools on demand. In-space manufacturing (ISM) through 3D printing is being explored by NASA's Marshall Space Flight Center (MSFC) and commercial partners, with support from the NASA Ames Research Center physics-based modeling group.

In an essential moment for space exploration, a unique project made its mark in 2014 with the first-ever 3D printer onboard the International Space Station. This groundbreaking technology, developed by Made in Space, employed a cutting-edge fused filament fabrication (FFF) process, a form similar to Fused Deposition Modeling (FDM). The FFF method involves continuously feeding a plastic thread through a heated extruder expertly layering it onto a tray to form intricate three-dimensional objects.

Under the banner of "3-D Printing in Zero-G" investigation, this daring project yielded man-printed components. Researchers examined and compared these components made on the ISS with their counterparts manufactured on Earth. They discovered that microgravity exhibited no engineering-significant impact on the 3D printing process. Comparing both ISS and Earth designs showed the same structural integrity and design performance, which is truly remarkable.

This announcement signifies a momentous breakthrough, affirming that 3D printers function seamlessly in the challenging microgravity environment of space. The implications of this achievement are profound and opens the doors to revolutionary logistics systems for extended space missions.

This pioneering endeavor has paved the way for a new era in space exploration, where essential components and tools can be created in real-time, reducing reliance on Earth-based supply chains. As we look to the future of long-duration missions and interplanetary exploration, the successful integration of 3D printing in space heralds a transformative chapter in the quest to conquer the cosmos. In our next article, we discover the first 3D-printed object and how it has changed the Space industry for the Astronauts aboard the ISS.

Do you believe Additive Manufacturing will provide an opportunity for astronauts to live on the moon?