Cranfield University is currently engaged in a collaborative revolution as part of an international project.
This project entails the deployment of a specially designed 3D metal printer, comparable in size to a microwave, to the International Space Station. Powered by lasers, the primary objective of this endeavor is to acquire valuable knowledge regarding the impact of microgravity on the printer’s performance.
It is believed by scientists that the future will witness the utilization of Additive Manufacturing to print 3D metal parts on board the ISS, thereby facilitating the rapid replacement or creation of components. This advanced technique would eliminate the costly and time-consuming practice of physically transporting parts to space.
The trial of 3D metal printers utilising high-powered lasers in a space environment marks an unprecedented endeavour. By scrutinising the data collected from this experiment, scientists aim to gain insights into how the microgravity environment affects the printing process and the characteristics of the metal produced.
The printer’s melting process and hardware, along with its laser source, delivery optics, feedstock storage, and feeding system, were all designed by Cranfield academics. The manufacturing experts took great care to mitigate risk factors such as heat transfer. Overcoming the obstacle of low power availability, they devised an efficient process for melting metals. Leading the design efforts for the printer was Dr. Wojciech Suder, a Senior Lecturer in Laser Processing and Additive Manufacturing at Cranfield University’s Welding and Additive Manufacturing Centre.
Previous experiments have assessed the impact of gravity on liquids in space, but the same analysis has not been conducted when printing components from liquid metal form due to the high temperatures involved. As a result, our task was to design a printer that is thermally neutral and does not emit heat or radiation onto the ISS. This endeavour involved meeting multiple requirements and ensuring full autonomy, which presented a considerable challenge. Nonetheless, we have successfully accomplished this task and are now awaiting the return of the samples for further analysis.
The objective is to assess the influence of microgravity on 3D metal printing in order to ascertain the most effective utilisation of this technology in future space endeavours. The process of metal printing in space is widely recognized as a formidable task, primarily due to the immense energy and material requirements. Nevertheless, this innovative concept has the potential to greatly enhance our ability to sustain and repair spacecraft.
Cranfield’s contribution serves as a testament to the invaluable skills and expertise that the UK brings to the field of global space exploration. We eagerly await the forthcoming stages of this captivating technology.
The European Space Agency commissioned the Metal3D five-year project, which was spearheaded by Airbus Defence and Space in collaboration with Cranfield University, AddUp, and Hightech. This initiative aimed to advance the field of metal 3D printing technology.
The progress made in the field of clean space technology owes a great deal to the application of systems engineering. The development of drag sails, a truly innovative technology, is built upon the solid foundation of excellent systems engineering. This encompasses a range of activities, starting from the initial mission design, defining the necessary requirements, and advancing the technology to effectively address the issue of space debris. Furthermore, systems engineering also encompasses the creation of clean space technologies, on-orbit operations, and various tasks such as servicing, manufacturing, assembly, and recycling.
The utilization of Model-Based Systems Engineering (MBSE) in the development of planetary rover systems entails the implementation of MBSE methodologies. These methodologies are utilized in the design and modeling of the system architecture. The selection of system components and the overall system design are determined by the system requirements identified in the initial phase of the project. The resulting architecture showcases the detailed interactions between different sub-systems and layers. This undertaking aims to present a comprehensive illustration of the application of MBSE methodology in the conceptualization and architectural phases of a project, utilizing the planetary rover as a specific use case.