Jump to content

Recommended Posts

  • Publishers
Posted
4 Min Read

3D Printing: Saving Weight and Space at Launch

first-metal-part-3d-printed-in-space.jpg
The first metal part 3D printed in space.
Credits: ESA

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.

Epps is wearing a long-sleeved black top and pants, a black headband, goggles, and blue latex gloves and has a tablet attached by Velcro to her pants. In her right hand she holds a small metal disk with six 3D printed posts of different shapes and lengths protruding from it.
NASA astronaut Jeanette Epps configures the Metal 3D Printer to produce experimental samples from stainless steel.
NASA

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

Astronaut Barry (Butch) Wilmore holds a ratchet wrench inside the space station
NASA Astronaut Butch Wilmore holds a ratchet wrench created with the 3D Printing in Zero-G printer.
NASA

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

McClain, wearing a red, black, and white striped polo shirt, has her back to the camera as she pushes a large silver box into a space on the station wall next to other equipment. There is a large cord and a control panel on the front of the box.
NASA astronaut Anne McClain installs the Refabricator in Feb. 2019.
NASA

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.

A metal box about the size of a microwave oven, sits on a gray work surface. A door on its front is open, revealing the metal printing mechanism inside. There is a white control panel to the right of the door. A laboratory in the background is blurred and bathed in red light.
The Redwire Regolith Print facility before launch to the space station.
Redwire Space

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.

View the full article

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By NASA
      3 Min Read NASA Invests in Future STEM Workforce Through Space Grant Awards 
      NASA is awarding up to $870,000 annually to 52 institutions across the United States, the District of Columbia, and Puerto Rico over the next four years. The investments aim to create opportunities for the next generation of innovators by supporting workforce development, science, technology, engineering and math education, and aerospace collaboration nationwide. 
      The Space Grant College and Fellowship Program (Space Grant), established by Congress in 1989, is a workforce development initiative administered through NASA’s Office of STEM Engagement (OSTEM). The program’s mission is to produce a highly skilled workforce prepared to advance NASA’s mission and bolster the nation’s aerospace sector. 
      “The Space Grant program exemplifies NASA’s commitment to cultivating a new generation of STEM leaders,” said Torry Johnson, deputy associate administrator of the STEM Engagement Program at NASA Headquarters in Washington. “By partnering with institutions across the country, we ensure that students have the resources, mentorship, and experiences needed to thrive in the aerospace workforce.” 
      The following is a complete list of awardees: 
      University of Alaska, Fairbanks  University of Alabama, Huntsville  University of Arkansas, Little Rock  University of Arizona  University of California, San Diego  University of Colorado, Boulder  University of Hartford, Connecticut  American University, Washington, DC  University of Delaware  University of Central Florida  Georgia Institute of Technology  University of Hawaii, Honolulu  Iowa State University, Ames  University of Idaho, Moscow  University of Illinois, Urbana-Champaign  Purdue University, Indiana  Wichita State University, Kansas  University of Kentucky, Lexington  Louisiana State University and A&M College  Massachusetts Institute of Technology  Johns Hopkins University, Maryland  Maine Space Grant Consortium  University of Michigan, Ann Arbor  University of Minnesota  Missouri University of Science and Technology  University of Mississippi  Montana State University, Bozeman  North Carolina State University  University of North Dakota, Grand Forks  University of Nebraska, Omaha  University of New Hampshire, Durham  Rutgers University, New Brunswick, New Jersey  New Mexico State University  Nevada System of Higher Education  Cornell University, New York  Ohio Aerospace Institute  University of Oklahoma  Oregon State University  Pennsylvania State University  University of Puerto Rico  Brown University, Rhode Island  College of Charleston, South Carolina  South Dakota School of Mines & Technology  Vanderbilt University, Tennessee  University of Texas, Austin  University of Utah, Salt Lake City  Old Dominion University Research Foundation, Virginia  University of Vermont, Burlington  University of Washington, Seattle  Carthage College, Wisconsin  West Virginia University  University of Wyoming  Space Grant operates through state-based consortia, which include universities, university systems, associations, government agencies, industries, and informal education organizations engaged in aerospace activities. Each consortium’s lead institution coordinates efforts within its state, expanding opportunities for students and researchers while promoting collaboration with NASA and aerospace-related industries nationwide. 
      To learn more about NASA’s missions, visit: https://www.nasa.gov/ 

      View the full article
    • By NASA
      Inside a laboratory in the Space Systems Processing Facility at NASA’s Kennedy Space Center in Florida, a payload implementation team member harvests ‘Outredgeous’ romaine lettuce growing in the Advanced Plant Habitat ground unit on Thursday, April 24, 2025. The harvest is part of the ground control work supporting Plant Habitat-07, which launched to the International Space Station aboard NASA’s SpaceX 31st commercial resupply services mission.
      The experiment focuses on studying how optimal and suboptimal moisture conditions affect plant growth, nutrient content, and the plant microbiome in microgravity. Research like this continues NASA’s efforts to grow food that is not only safe but also nutritious for astronauts living and working in the harsh environment of space.
      The ‘Outredgeous’ romaine lettuce variety was first grown aboard the space station in 2014, and Plant Habitat-07 builds on that legacy, using the station’s Advanced Plant Habitat to expand understanding of how plants adapt to spaceflight conditions. Findings from this work will support future long-duration missions to the Moon, Mars, and beyond, and could also lead to agricultural advances here on Earth.
      Image credit: NASA/Kim Shiflett
      View the full article
    • By NASA
      NASA In this photo taken on Feb. 8, 1984, NASA astronaut Ronald E. McNair plays his saxophone while off-duty during the STS-41B mission. He and fellow crew members Vance D. Brand, Robert L. Gibson, Robert L. Stewart, and Bruce McCandless II launched on the space shuttle Challenger from NASA’s Kennedy Space Center in Florida on Feb. 3, 1984. During the mission, McCandless and Stewart performed the first untethered spacewalks.
      McNair, who was nationally recognized for his work in laser physics, was selected as an astronaut candidate in January 1978. He completed a one-year training and evaluation period in August 1979, qualifying him for assignment as a mission specialist astronaut on space shuttle flight crews. STS-41B was his first flight.
      Check out STS-41B mission highlights, narrated by the crew.
      Image credit: NASA
      View the full article
    • By NASA
      Crew members are kicking off operations for several biological experiments that recently launched to the International Space Station aboard NASA’s 32nd SpaceX commercial resupply services mission. These include examining how microgravity affects production of protein by microalgae, testing a microscope to capture microbial activity, and studying genetic activity in biofilms.
      Microalgae in microgravity
      Sophie’s BioNutrients This ice cream is one of several products made with a protein powder created from Chorella microalgae by researchers for the SOPHONSTER investigation, which looks at whether the stress of microgravity affects the algae’s protein yield. Microalgae are nutrient dense and produce proteins with essential amino acids, beneficial fatty acids, B vitamins, iron, and fiber. These organisms also can be used to make fuel, cooking oil, medications, and materials. Learning more about microalgae growth and protein production in space could support development of sustainable alternatives to meat and dairy. Such alternatives could provide a food source on future space voyages and for people on Earth and be used to make biofuels and bioactive compounds in medicines.
      Microscopic motion
      Portland State University These swimming microalgae are visible thanks to the Extant Life Volumetric Imaging System or ELVIS, a fluorescent 3D imaging microscope that researchers are testing aboard the International Space Station. The investigation studies both active behaviors and genetic changes of microscopic algae and marine bacteria in response to spaceflight. ELVIS is designed to autonomously capture microscopic motion in 3D, a capability not currently available on the station. The technology could be useful for a variety of research in space and on Earth, such as monitoring water quality and detecting potentially infectious organisms.
      Genetics of biofilms
      BioServe This preflight image shows sample chambers for the Genetic Exchange in Microgravity for Biofilm Bioremediation (GEM-B2) investigation, which examines the mechanisms of gene transfer within biofilms under microgravity conditions. Biofilms are communities of microorganisms that collect and bind to a surface. They can clog and foul water systems, often leave a residue that can cause infections, and may become resistant to antibiotics. Researchers could use results from this work to develop genetic manipulations that inhibit biofilm formation, helping to maintain crew health and safety aboard the International Space Station and on future missions.
      Learn more about microgravity research and technology development aboard the space station on this webpage.
      Keep Exploring Discover More Topics From NASA
      Space Station Research and Technology
      Latest News from Space Station Research
      Space Station Research Results
      NASA Science, Cargo Launch on 32nd SpaceX Resupply Station Mission
      View the full article
    • By European Space Agency
      Video: 00:00:00 ESA’s state-of-the-art Biomass satellite launched aboard a Vega-C rocket from Europe’s Spaceport in Kourou, French Guiana. The rocket lifted off on 29 April 2025 at 11:15 CEST (06:15 local time).
      In orbit, this latest Earth Explorer mission will provide vital insights into the health and dynamics of the world’s forests, revealing how they are changing over time and, critically, enhancing our understanding of their role in the global carbon cycle. It is the first satellite to carry a fully polarimetric P-band synthetic aperture radar for interferometric imaging. Thanks to the long wavelength of P-band, around 70 cm, the radar signal can slice through the whole forest layer to measure the ‘biomass’, meaning the woody trunks, branches and stems, which is where trees store most of their carbon.
      Vega-C is the evolution of the Vega family of rockets and delivers increased performance, greater payload volume and improved competitiveness.
      View the full article
  • Check out these Videos

×
×
  • Create New...