About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Materials and Manufacturing in Space
|
| Presentation Title |
Development of net-shape wire based additive manufacturing for the International Space Station |
| Author(s) |
Wojciech Suder, Stewart Williams |
| On-Site Speaker (Planned) |
Wojciech Suder |
| Abstract Scope |
Transferring manufacturing processes developed on Earth directly to space is challenging due to significant differences in process behaviour, strict safety and robustness requirements.
In this project, an international consortium developed the first-ever metal 3D printer for space applications. The development began with advanced computational modelling of melt pool behaviour and the energy balance required to manage the melting process within a reliable and efficient processing regime. The main challenges included melting metal with the lowest possible energy consumption and ensuring maximum robustness and safety during autonomous operation.
In January 2024, the printer was successfully launched and commissioned on board the International Space Station, with the first specimens printed in August 2024. Several samples have been produced to study the effects of gravity on process behaviour and the mechanical properties of the manufactured parts. This project highlights the various technical and fundamental challenges our team overcame during an eight-year journey. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Other, Modeling and Simulation |