Since the 20th century, humans have been fascinated by exploring space and learning about what lies beyond Earth. This article mainly introduces some of the work of NASA (National Space Agency) and ESA (European Space Agency) in space exploration. A big player in this conquest is 3D printing. The technique is gaining popularity in aerospace because of its ability to produce complex parts quickly and at low cost. It can be used to make things like satellites, space suits and rocket components. In fact, according to SmarTech, the market value of additive manufacturing in the private space industry is expected to reach €2.1 billion by 2026. This begs the question: How can 3D printing help humans be more prominent in space?
Initially, 3D printing was mainly used for rapid prototyping in the medical, automotive and aerospace sectors. However, as the technology spreads, it is increasingly used in end-use components. Metal additive manufacturing techniques, in particular laser powder bed fusion (L-PBF), have allowed the production of a wide range of metal parts with properties and resistances suitable for extreme space conditions. Other 3D printing techniques, such as directed energy deposition (DED), binder jetting and extrusion processes, are also used to manufacture aerospace components. In recent years, new business models have emerged, with companies such as Made in Space and Relativity Space using 3D printing to design and manufacture aerospace components.
△Relativity Space develops 3D printers for the aerospace industry (Source: Relativity Space)
3D Technology in Aerospace
Let's take a closer look at the various 3D printing technologies used in the aerospace industry. First of all, it should be pointed out that metal additive manufacturing, especially L-PBF, is the most widely used in this field. The process uses laser energy to fuse metal powder together layer by layer. It is especially suitable for the production of small, complex, delicate and customized parts. Aerospace manufacturers can also benefit from DED, which deposits metal wire or powder, primarily for repair, coating or production of custom metal or ceramic components.
In contrast, binder jetting, despite its advantages in terms of production speed and low cost, is not suitable for producing parts with high mechanical properties. This is because it requires a post-processing strengthening step, which increases the manufacturing time of the final product. Extrusion technology is also effective in the space environment, but not all polymers are suitable for use in space, and high-performance plastics such as PEEK can replace some metal parts due to their strength. However, this 3D printing process is still not widely available, but it could become a valuable asset for space exploration through the use of new materials.
△Laser fusion on a powder bed is a widely used process in aerospace 3D printing (Image source: DMG Mori)
