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French OEM AddUpAirbus, in collaboration, has DeliveryThe European Space Agency (ESA) has received the first metal 3D space printer. This printer was launched on NASA’s Mission NG-20, bound for the International Space Station (ISS) aboard a SpaceX Falcon 9 rocket. The printer was specially designed to work in microgravity. It will play a vital role in the Huginn missionAndreas Mogensen is an ESA astronaut and Falcon 9 Pilot, who will be 3D printing in space with the Columbus European Science module crew.
AddUp and Airbus are developing a new product with assistance from Cranfield UniversityAerospace contractor Highftech EngineeringThe printer is a DED (wire directed energy deposition) system. The design of the printer incorporates a wire cartridge, while minimising heat and particle emissions and compensating motion. This printer is expected to start operations as soon as next month. It represents a significant advance in metal 3D-printing for space applications.
Prior explorations of space-oriented metal 3-D printing focused on technologies such as electron beam melting to repair spare parts. This new printer represents a crucial technological step forward. This is especially true as space missions continue to become longer, more expensive, and more critical. This printer’s ability to not only repair broken parts, but also create improvised parts for unforeseen emergencies or upgrades can be a game changer. Duck Tape and crew ingenuity have prevented several space disasters. The introduction of 3D-printing in space opens the door to more effective and custom solutions.
If humans want to colonize another planet, mine in space and generate energy in orbit or manage thousands of satellites, 3D printing is a must-have tool. Its importance in reducing the amount of cargo needed for missions, recycling metals onboard, and fabricating items on demand can’t be overstated. This technology is a great way to improve mission efficiency. It produces parts on site and on time, a solution that is much faster than launching new supply flights, which can be vital in saving lives and prolonging missions.
In the context of an eventual mission to Mars, 3D-printed solutions are critical due to the inevitability that unforeseen disasters will occur. While space exploration is more accessible, the impact on equipment failures and psychological and physical stress are enormous. We mustn’t forget 15 astronautsSixty-six astronauts, some of whom have been on multiple missions, have lost their lives.
“The development of the Metal 3D printer relies on the unique multidisciplinary expertise of AddUp’s engineers and researchers. Our staff is highly skilled in a wide range of additive manufacturing processes. They are also experts in machine design, programming, and optimization. Our teams have helped develop this first space metal 3-D printer that will soon be in orbit. The metal 3D printer has been designed and optimized to meet the conditions and environment of the International Space Station”“AddUp was chosen for this project based on a long history and partnership rooted in exploration and innovation,” said AddUp Technical Director Sébastien Devroe.
“We were confident that with the knowledge and experience the AddUp team has, combined with the technological expertise of Airbus, together we would be successful in delivering a high quality and efficient metal 3D printer to support the exploration of space,” stated Elodie Viau, Head of Engineering at Airbus Space Systems.
The future of 3D printing technology will be greatly enhanced by the upcoming tests comparing 3D parts printed in space with those produced on Earth. One of the most intriguing aspects is the potential that microgravity can enhance layer adhesion. This could lead to a major breakthrough in this field. This is an important step for our tech.
Beyond metal additive manufacture (AM), it is necessary to further develop polymer 3D-printing from recycled materials, and advance bioprinting. The fact that AM is a critical tool in space exploration is a testament not only to its credibility but also to the industry’s ability to capitalize on an expanding space market.
This venture offers a unique chance for DED processes and wire laser deposition. These technologies, which are often perceived as less refined than powder bed fusion, will gain more prestige, funding and attention. DED and wire-based technologies stand out for their safety, versatility and ability to use recycled materials with varying qualities and characteristics. The ability of a DED laser system to act as a cutting or marking tool is another advantage. DED’s capability in part rejuvenation, by adding new layers to worn parts, is also beneficial.
The increased scrutiny and tests in the space context might attract new customers, especially from the aerospace and defense sectors. This could encourage them to see DED in a different light. All things being equal, 3D printing is having a very good year.
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