3D Printing: Saving Weight and Space at Launch

4 Min Read

3D Printing: Saving Weight and Space at Launch

Science in Space March 2025

Additive manufacturing, also known as 3D printing, is regularly used on the ground to quickly produce a variety of devices. Adapting this process for space could let crew members create tools and parts for maintenance and repair of equipment on the spot, rather than trying to bring along every item that might be needed.

The ability to manufacture things in space is especially important in planning for missions to the Moon and Mars because additional supplies cannot quickly be sent from Earth and cargo capacity is limited.

Research on the International Space Station is helping to develop the capability to address multiple needs using 3D printing.

Metal 3D Printer, a current investigation from ESA (European Space Agency), tests 3D printing of small metal parts in microgravity. Results could improve understanding of the function, performance, and operations of 3D printing in space with metal, as well as the quality, strength, and characteristics of printed parts. This work also could benefit applications on Earth that use metal, such as the automotive, aeronautical, and maritime industries.

Printing with plastic

3D Printing in Zero-G sent the first 3D printer, developed by NASA’s Marshall Space Flight Center and Redwire (formerly Made in Space), to the space station in 2014. The printer used a process that feeds a continuous thread of plastic through a heated extruder and onto a tray layer by layer to create an object. The investigation produced more than a dozen parts, including a ratchet wrench, showing that researchers could send a design from the ground to the system on the station more than 200 miles above.

Comparing the parts made in space with those made on the ground showed that microgravity had no significant effect on the process.

Redwire then developed the Additive Manufacturing Facility (AMF), sent to the station in 2015. Researchers evaluated its mechanical performance and found improvements in tension strength and flexibility compared to the earlier demonstration, helping to further the technology for this type of manufacturing on Earth and in space.

In 2015 and 2016, Portable On Board 3D Printer tested an automated printer developed by the Italian Space Agency to produce plastic objects in space. The investigation provided insight into how the material behaves in microgravity, which could support development of European additive manufacturing technology for use in space.

Printing with other materials

Another approach is recycling plastic – for example, turning a used 3D-printed wrench into a spoon and creating items from the plastic bags and packing foam needed to send supplies to space. This technology could help reduce the amount of raw material at launch and cut down on the volume of waste that must be disposed of on long journeys. The Refabricator, a machine created by Tethers Unlimited Inc, tested this approach and successfully manufactured its first object. Some issues occurred in the bonding process, likely caused by microgravity, but assessment of the material could help determine whether there are limits to how many times plastic can be re-used. Ultimately, researchers plan to create a database of parts that can be manufactured using the space station’s capabilities.

Redwire Regolith Print (RRP) tested another kind of feedstock for 3D manufacturing in orbit, a simulated version of regolith, the dust present on the surface of the Moon and other planetary bodies. Results could lead to development of technology for using regolith to construct habitats and other structures rather than bringing raw materials from Earth.

The space station also has hosted studies of a form of 3D printing called biological printing or bioprinting. This process uses living cells, proteins, and nutrients as raw materials to potentially produce human tissues for treating injury and disease, which could benefit future crews and patients on Earth.

Other manufacturing techniques tested on the orbiting lab include producing optical fibers and growing crystals for synthesizing pharmaceuticals and fabricating semiconductors.

Powered by WPeMatico

Get The Details…
Christian M. Getteau

Hubble Captures a Neighbor’s Colorful Clouds

Say hello to one of the Milky Way’s neighbors! This NASA/ESA Hubble Space Telescope image features a scene from one of the closest galaxies to the Milky Way, the Small Magellanic Cloud (SMC). The SMC is a dwarf galaxy located about 200,000 light-years away. Most of the galaxy resides in the constellation Tucana, but a small section crosses over into the neighboring constellation Hydrus.

Thanks to its proximity, the SMC is one of only a few galaxies that are visible from Earth without the help of a telescope or binoculars. For viewers in the southern hemisphere and some latitudes in the northern hemisphere, the SMC resembles a piece of the Milky Way that has broken off, though in reality it’s much farther away than any part of our own galaxy.

With its 2.4-meter mirror and sensitive instruments, Hubble’s view of the SMC is far more detailed and vivid than what humans can see. Researchers used Hubble’s Wide Field Camera 3 to observe this scene through four different filters. Each filter permits different wavelengths of light, creating a multicolored view of dust clouds drifting across a field of stars. Hubble’s view, however, is much more zoomed-in than our eyes, allowing it to observe very distant objects. This image captures a small region of the SMC near the center of NGC 346, a star cluster that is home to dozens of massive young stars.

Media Contact:

Claire Andreoli (claire.andreoli@nasa.gov)
NASA’s Goddard Space Flight Center, Greenbelt, MD

Keep Exploring

Discover More Topics From Hubble

Hubble Space Telescope

Since its 1990 launch, the Hubble Space Telescope has changed our fundamental understanding of the universe.

Hubble’s Night Sky Challenge

Hearing Hubble

Reshaping Our Cosmic View: Hubble Science Highlights

Powered by WPeMatico

Get The Details…

Sols 4484-4485: Remote Sensing on a Monday

Written by Conor Hayes, Graduate Student at York University

Earth planning date: Monday, March 17, 2025

Last week I was in Houston, Texas, at the Lunar and Planetary Science Conference. The mid-March weather in Houston is often more like mid-summer weather here in Toronto, so it has been a bit of a shock coming home to temperatures that are hovering around freezing rather than being in the upper 20s (degrees Celsius, or the low to mid 80s for those of you still using Fahrenheit). Still, Toronto is positively balmy compared to Gale Crater, where temperatures usually range between minus 80°C and minus 20°C (or minus 110°F to minus 5°F) during this part of the year. These cold temperatures and their associated higher demands on the rover’s available power for heating are continuing to motivate many of the decisions that we make during planning.

We received the double good news this morning that the weekend’s drive completed successfully, including the mid-drive imaging of the other side of “Humber Park” that Michelle mentioned in Friday’s blog, and that our estimates of the weekend plan’s power consumption ended up being a little conservative. So we started planning exactly where we wanted to be, and with more power to play around with than we had expected. Yay!

The weekend’s drive left us parked in front of some rocks with excellent layering and interesting ripples that we really wanted to get a closer look at with MAHLI. (See the cover image for a look at these rocks as seen by Navcam.) Sadly, we also ended up parked in such a way that presented a slip hazard if the arm was unstowed. As much as we would have loved to get close-up images of these rocks, we love keeping Curiosity’s arm safe even more, so we had to settle for a remote sensing-only plan instead.

Both the geology and mineralogy (GEO) and the environmental science (ENV) teams took full advantage of the extra power gifted to us today to create a plan packed full of remote sensing observations. Because we’re driving on the first sol of this two-sol plan, any “targeted” observations, i.e. those where we know exactly where we want to point the rover’s cameras, must take place before the drive. The first sol is thus packed full of Mastcam and ChemCam observations, starting with a 14×3 Mastcam mosaic of the area in front of us that’s outside of today’s workspace. Individual targets then get some Mastcam love with mosaics of various ripple and layering features at “Verdugo Peak,” “Silver Moccasin Trail,” and “Jones Peak.” Mastcam and ChemCam also team up on a LIBS target, “Trancas Canyon,” and some more long-distance mosaics of Gould Mesa, a feature about 100 meters away from us (about 328 feet) that we’ll be driving to the south of as we continue to head toward the “boxwork” structures.

After a drive, there often aren’t many activities scheduled other than the imaging of our new location that we’ll need for the next planning day. However, in this plan ENV decided to take advantage of the fact that Navcam observations can take place at the same time that the rover is talking to one of the spacecraft that orbit Mars. This is a useful trick when power is tight as it allows us to do more science without adding additional awake time (since the rover needs to be awake anyway to communicate with the orbiters). Today, it’s being used to get some extra cloud observations right before sunset, a time that we don’t often get to observe. These observations include a zenith movie that looks straight up over the rover and a “phase function sky survey,” which takes a series of nine movies that form a dome around the rover to examine the properties of the clouds’ ice crystals. 

The second sol of this plan is much more relaxed, as post-drive sols often are because we don’t know exactly where we’ll be after a drive. Today, we’ve just got our usual ChemCam AEGIS activity, followed by a pair of Navcam cloud and cloud shadow movies to measure the altitude of clouds over Gale. As always, we’ve also got our usual set of REMS, RAD, and DAN activities throughout this plan.

Explore More

2 min read

Sols 4481-4483: Humber Pie

Article


2 days ago

3 min read

Sols 4479-4480: What IS That Lumpy, Bumpy Rock?

Article


6 days ago

3 min read

Navigating a Slanted River

Article


1 week ago

Keep Exploring

Discover More Topics From NASA

Mars

Mars is the fourth planet from the Sun, and the seventh largest. It’s the only planet we know of inhabited…

All Mars Resources

Explore this collection of Mars images, videos, resources, PDFs, and toolkits. Discover valuable content designed to inform, educate, and inspire,…

Rover Basics

Each robotic explorer sent to the Red Planet has its own unique capabilities driven by science. Many attributes of a…

Mars Exploration: Science Goals

The key to understanding the past, present or future potential for life on Mars can be found in NASA’s four…

Powered by WPeMatico

Get The Details…

NASA Selects 14 Finalist Teams for the 2025 RASC-AL Competition

Fourteen university teams have been selected as finalists for NASA’s 2025 Revolutionary Aerospace Systems – Academic Linkage (RASC-AL) Competition. This year’s competition invited undergraduate and graduate students from across the nation to develop new, innovative concepts to improve our ability to operate on the Moon, Mars, and beyond. Finalists will present their proposed concepts to a panel of NASA and aerospace industry leaders.  

The 2025 Finalists are: 

• Sustained Lunar Evolution – An Inspirational Moment: 

• Massachusetts Institute of Technology, “M.I.S.T.R.E.S.S. – Moon Infrastructure for Sustainable Technologies, Resource Extraction, and Self-Sufficiency” 

• Tulane University, “Scalable Constructs for Advanced Lunar Activities and Research (SCALAR)” 

• Virginia Polytechnic Institute and State University, “Project Aeneas” 

• Virginia Polytechnic Institute and State University, “Project Khonsu” 

• Advanced Science Missions and Technology Demonstrators for Human-Mars Precursor Campaign:  

• Auburn University, “Dynamic Ecosystems for Mars ECLSS Testing, Evaluation, and Reliability (DEMETER)” 

• University of Illinois, Urbana-Champaign, “MATER: Mars Architecture for Technology Evaluation and Research” 

• Virginia Polytechnic Institute and State University, “Project Vehicles for Engineering Surface Terrain Architectures (VESTA)” 

• Small Lunar Servicing and Maintenance Robot:  

• Arizona State University, “DIANA – Diagnostic and Intelligent Autonomously Navigated Assistant” 

• South Dakota State University, “Next-gen Operations and Versatile Assistant (NOVA)” 

• South Dakota State University, “MANTIS: Maintenance and Navigation for Technical Infrastructure Support” 

• Texas A&M University, “R.A.M.S.E.E.: Robotic Autonomous Maintenance System for Extraterrestrial Environments” 

• University of Maryland, “Servicing Crane Outfitted Rover for Payloads, Inspection, Operations, N’stuff (SCORPION)” 

• University of Puerto Rico, Mayagüez, “Multi-functional Operational Rover for Payload Handling and Navigation (MORPHN)” 

• Virginia Polytechnic Institute & State University, “Adaptive Device for Assistance and Maintenance (ADAM)” 

The RASC-AL Competition is designed to engage university students and academic institutions in innovation within the field of aerospace engineering. By providing a platform for students to develop and present their ideas, NASA aims to cultivate foundational research for new concepts and technologies for the future of space exploration. This year’s RASC-AL projects include scalable lunar infrastructure and services, a lunar robot that can work autonomously or be controlled remotely, and a concept for a science or technology demonstration mission using human-scale launch, transportation, entry, and landing capabilities at Mars. All of these functions are critical to future NASA missions. 

“This year’s RASC-AL projects are not just academic exercises; they will contribute real solutions to some of the most pressing challenges we currently face. The competition continues to highlight the importance of innovation and interdisciplinary collaboration in aerospace,” said Daniel Mazanek, RASC-AL program sponsor and senior space systems engineer from NASA’s Langley Research Center in Hampton, VA. 

These finalist teams will move forward to the next phase of the competition, where they will prepare and submit a detailed technical paper outlining their designs, methodologies, and anticipated impacts. Each team will present their concepts at the 2025 RASC-AL Competition Forum in June 2025 showcasing their work to a judging panel of NASA and industry experts for review and discussion. 

“The ingenuity and out-of-the-box designs showcased by these students is inspiring,” added Dr. Christopher Jones, RASC-AL program sponsor and chief technologist for the Systems Analysis and Concepts Directorate at NASA’S Langley  “We are excited to see how their ideas can contribute to NASA’s ongoing missions and future exploration goals. This is just the beginning of their journey, and we are proud to be part of it.” 

To learn more about NASA’s RASC-AL Competition, visit NASA’s RASC-AL Competition Website. RASC-AL is sponsored by the Strategy and Architecture Office within the Exploration Systems Development Mission Directorate at NASA Headquarters, and by the Space Mission Analysis Branch within the Systems Analysis and Concepts Directorate at NASA’s Langley Research Center. It is administered by the National Institute of Aerospace. 

Genevieve Ebarle / Victoria O’Leary
National Institute of Aerospace

Powered by WPeMatico

Get The Details…
Joseph Scott Atkinson