In 2014, NASA, in partnership with Made In Space, Inc., launched the first 3D printer to the International Space Station. Results of the first phase of operations for this mission demonstrated use of the fused filament fabrication (FFF) process for 3D printing in a microgravity environment. Previously published results indicated differences in density and mechanical properties of specimens printed in microgravity and those manufactured with the printer prior to its launch to ISS. Based on extensive analyses, these differences were hypothesized to be a result of subtle changes in manufacturing process settings rather than a microgravity influence on the FFF process. Phase II operations provided an opportunity to produce additional specimens in microgravity, evaluate the impact of changes in the extruder standoff distance, and ultimate provide a more rigorous assessment of microgravity effects through control of manufacturing process settings. Based on phase II results and a holistic consideration of phase I and phase II flight specimens, no engineering-significant microgravity effects on the process are noted. Results of accompanying material modeling efforts, which simulate the FFF process under a variety of conditions (including microgravity), are also presented. No significant microgravity effects on material outcomes are noted in the physics-based model of the FFF process. The 3D printing in zero G technology demonstration mission represents the first instance of off-world manufacturing. It represents the first step toward transforming logistics for long duration space exploration and is also an important crew safety enhancement for extended space missions where cargo resupply is

Purpose Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human space exploration. The purpose of this mission is to prove out the fused deposition modeling (FDM) process in the microgravity environment, evaluate microgravity effects on the materials manufactured, and provide the first demonstration of on-demand manufacturing for space exploration. Design/methodology/approach In 2014, NASA, in cooperation with Made in Space, Inc., launched a 3D printer to the ISS with the goal of evaluating the effect of microgravity on the fused deposition modeling (FDM) process and prove out the technology for use on long duration, long endurance missions where it could leveraged to reduce logistics requirements and enhance crew safety by enabling a rapid response capability. This paper presents the results of testing of the first phase of prints from the technology demonstration mission, where 21 parts where printed on orbit and compared against analogous specimens produced using the printer prior to its launch to ISS. Findings Mechanical properties, dimensional variations, structural differences and chemical composition for ground and flight specimens are reported. Hypotheses to explain differences observed in ground and flight prints are also developed. Phase II print operations, which took place in June and July of 2016, and ground-based studies using a printer identical to the hardware on ISS, will serve to answer remaining questions about the phase I data set. Based on Phase I analyses, operating the FDM process in microgravity has no substantive effect on the material produced. Practical implications Demonstrates that there is no discernable, engineering significant effect on operation of FDM in microgravity. Implication is that material characterization activities for this application can be ground-based. Originality/value Summary of results of testing of parts from the first operation of 3D printing in a microgravity environment.

The in-space manufacturing project at NASA Marshall Space Flight Center seeks to mature the manufacturing capabilities which will be needed on long duration, long endurance human spaceflight missions. The ability to manufacture materials and parts in space rather than launching them from earth has the potential to reduce logistics requirements and enhance crew safety. The International Space Station serves as a unique orbiting test bed for in-space manufacturing technology development for NASA and its commercial partners. This paper provides an overview of the projects currently in the in-space manufacturing technology portfolio and key technology development efforts in the past year.

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on-demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA and Made in Space, Inc. are developing the 3D Printing In Zero-G payload as a Technology Demonstration for the International Space Station. The 3D Printing In Zero-G experiment will be the first machine to perform 3D printing in space. The greater the distance from Earth and the longer the mission duration, the more difficult resupply becomes; this requires a change from the current spares, maintenance, repair, and hardware design model that has been used on the International Space Station up until now. Given the extension of the ISS Program, which will inevitably result in replacement parts being required, the ISS is an ideal platform to begin changing the current model for resupply and repair to one that is more suitable for all exploration missions. 3D Printing, more formally known as Additive Manufacturing, is the method of building parts/ objects/tools layer-by-layer. The 3D Print experiment will use extrusion-based additive manufacturing, which involves building an object out of plastic deposited by a wire-feed via an extruder head. Parts can be printed from data files loaded on the device at launch, as well as additional files uplinked to the device while on-orbit. The plastic extrusion additive manufacturing process is a low-energy, low-mass solution to many common needs on board the ISS. The 3D Print payload will serve as the ideal first step to proving that process in space. It is unreasonable to expect NASA to launch large blocks of material from which parts or tools can be traditionally machined, and even more unreasonable to fly up specialized manufacturing hardware to perform the entire range of function traditionally machining requires. The technology to produce parts on demand, in space, offers unique design options that are not possible through traditional manufacturing methods while offering cost-effective, high-precision, low-unit on-demand manufacturing. Thus, Additive Manufacturing capabilities are the foundation of an advanced manufacturing in space roadmap.

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc.