3D printing in outer space

The current process for transporting devices into space is quite inefficient and expensive. This is because the structural components are primarily designed to withstand the high loads during the launch phase of a spacecraft. However, these structures are oversized for the subsequent operational life. Due to the high costs and limited space on a launch vehicle, alternative solutions are required. The Munich student team AIMIS-FYT has tackled this problem and is working on a 3D printing process for cost-effective production in space as part of its aerospace engineering degree programme. The students are using photoreactive resin and UV light, which hardens the resin. A 3D printer had to be designed and built for experimental tests of the process in zero gravity.

The Munich-based company utilises the weightlessness of space for its 3D printing process. Instead of printing layer by layer, the parts are created in a weightless state using the three-dimensional movement of the print head. This process, known as in-situ manufacturing, ensures an enormous weight reduction and material savings for the components. For the drive technology of the 3D printer, the young engineers relied on three drylin® SAW-linear axes from the 1040 series and a robolink® gearbox for the movement of the print head. The drylin® SAW-axis were particularly impressive due to their low weight and maintenance-free operation. A compact robolink® D-rotary axis with worm gearbox was installed in the printer so that the print filament can also be rotated. An energy chain from the easychain series is used to ensure that the cables on the printer are also safely protected. "The e-chain® expert helped us to select the right chain. We had to enter all the parameters for our application and were immediately given a practical overview of all possible energy chains and their service life in our application."