Tag: 3d printing

Report: 3D printing in space

10:44 am

A new report released today [pdf] from the space think tank Intro-act provides a nice detailed summary of the economic and technological state of 3D printing industry in space.

The report first outlines the types of 3D printing presently available, using plastics and metals, and then outlines the advantages of printing things in orbit rather than carrying them up from Earth. Essentially, 3D printers are the real version of replicators seen in sci-fi movies, except that reality requires much more complexity, including a whole range of different machines designed for specific materials and final products.

The report lists four companies of note:

Made in Space (acquired by Redwire Corp.), Relativity Space, and AI SpaceFactory are the leading companies in the 3-D printing segment. With the addition of Vaya Space, the list provides a more comprehensive overview of the companies that are pioneering the use of 3-D printing technology in the realm of space exploration and development, showcasing the diverse applications and innovative strategies being employed in this exciting field.

Each company appears to have a different focus. Redwire is developing 3D printers for use on ISS, Relativity developing 3D printers for building rocket components, and AI Spacefactory developing 3D printed space colonies for Mars or the Moon.

If I had to choose which company to bet on, my pick would be Relativity followed by Redwire. The former’s large 3D printing technology for rockets can be very easily shifted to other uses and products, giving it a product of great value far beyond space. Redwire meanwhile has already launched and operated printers on ISS, proving it can provide that technology to future space stations.

This industry is however in its infancy. As the private space stations presently under construction launch, their need for this technology will skyrocket, and thus there will be opportunities galore.

3 comments

New startup unveils 3D printer for making rocket tanks and fairings

10:02 am

Rosotics, a new startup focusing on providing manufacturing components for rocket companies, has now unveiled a prototype of its proposed 3D printer, dubbed Mantis, for making rocket tanks and fairings.

Mesa, Arizona-based Rosotics plans to begin delivering the Mantis in the third quarter of 2023 to customers who place $95,000 deposits and sign hardware-as-a-service contracts. After delivery, Rosotics “will install, maintain and upgrade your hardware over time without any cost to you,” LaRosa said.

While the Mantis can be configured for various tasks, the starting point is a one printhead to additively manufacture aluminum or steel structures ranging in size from 1.5 to 8 meters in diameter.

The idea is sell this manufacturing capability to rocket companies as well as other manufacturers who need large structures built. Rather than machining these large structures themselves, or have outside machining companies do it for them, the companies would buy Mantis to do it in-house instead.

Whether this model will work depends on price and operations. Is it cheaper and quicker to use this 3D printer to make large rocket parts, or traditional methods? Obviously, Rosotics thinks it is. We will find out if others think so if Rosotics survives.

One comment

Second stage on Relativity’s first launch fails to fire

9:36 am

The first test launch of Relativity’s 3D rocket, Terran-1, achieved the mission’s minimum goals, with the first stage performing exactly as planned and the 3D-printed rocket successfully completing engine cut-off and stage separation.

At that point the second stage engine failed to fire, and the upper stage fell into the ocean.

I have embedded the live stream from last night below. The company had made it clear that their number one goal for this flight was getting that 3D-printed rocket through max-q, the time when the atmospheric pressures on the rocket are their greatest. In this area the launch was a success.

This was also the first American launch of a methane-fueled rocket, and it was fascinating seeing the difference in the rocket’s plumes from other fuel types. Terran-1’s engine plumes were a clear distinct blue, quite different from the white and smokey plumes produced by solid-fueled and kerosene-fueled rocket engines, and the almost invisible plume of space shuttle’s hydrogen-fueled engines.

As yet, no methane-fueled rocket has reached orbit, though two Chinese companies and Relativity have tried. SpaceX will try itself when it launches Superheavy/Starship.
» Read more

3 comments

Researchers develop strongest-yet 3D printed titanium

10:21 am

Capitalism in space: Researchers at Monash University in Australia have successfully developed a 3D printed titanium alloy that has an internal strength exceeding that of normal commercially produced titanium.

In tests, the team demonstrated that the new titanium alloy had both elongation and tensile strengths (stretching and tension, respectively) of over 1,600 MPa. For reference, most commercial titanium alloys top out at around 1,000 MPa. This is also the highest specific strength for any other 3D-printed metal alloy, the team says.

Since 3D printing is going to be the main industrial manufacturing process in space, this process and the titanium it produces is certainly going to looked at with great interest by those who wish to build things in space. Imagine having a 3D printer that can make strong titanium parts in almost any needed shape. The possibilities are endless.

5 comments

Mitsubishi develops technology to 3D print cubesat antennas in space using sunlight

9:22 pm

Capitalism in space: Mitsubishi this week announced a new technology it had developed that will allow small cubesats to 3D print antennas in space much larger than the satellite itself, using the sun’s ultraviolet radiation to harden the resin.

The full press release can be read here [pdf].

– On-orbit manufacturing eliminates the need for an antenna structure that can withstand vibrations and shocks during launch, which is required for conventional antenna reflectors, making it possible to reduce the weight and thickness of antenna reflectors, thereby contributing to the reduction of satellite weight and launch costs.

– Assuming the use of a 3U CubeSat (100 x 100 x 300 mm) specification, an antenna reflector with a diameter of 165 mm, which is larger than the size of the CubeSat bus, was fabricated in air, and a gain of 23.5 dB was confirmed in the Ku band (13.5 GHz).

Obviously this is still in development, but once viable commercially it will expand the capabilities of cubesats enormously, especially for interplanetary missions which need larger antennas for communications.

8 comments

Redwire successfully 3D prints ceramic parts in space

9:22 am

Capitalism in space: Redwire announced today that it has successfully for the first time 3D printed several ceramic parts in space on ISS.

The commercially developed in-space manufacturing facility successfully operated with full autonomy using additive stereolithography (SLA) technology and pre-ceramic resins to manufacture a single-piece ceramic turbine blisk on orbit along with a series of material test coupons. The successful manufacture of these test samples in space is an important milestone to demonstrate the proof-of-potential for CMM to produce ceramic parts that exceed the quality of turbine components made on Earth. The ceramic blisk and test coupons will be stowed and returned to Earth for analysis, aboard the SpaceX Dragon CRS-21 spacecraft. CMM, developed by Redwire subsidiary Made In Space, is the first SLA printer to operate on orbit.

The replicators of Star Trek are coming. The real ones won’t be like the ones in the television show, nor will they be used to produce food, but they are coming nonetheless. It is quite likely that the colonization of space will demand a revolution in 3D printing that will make it possible for almost all heavy industry manufacturing.

Leave a comment

Made in Space purchased by venture capital company Redwire

10:06 am

Capitalism in space: Made in Space, which has specialized in developing 3D printing in space on ISS and elsewhere, has been acquired by a company dubbed Redwire that was created by a venture capital company.

AE Industrial Partners, a private equity firm, formally established Redwire at the beginning of June by combining two companies it had acquired, Adcole Space and Deep Space Systems (DSS). Both companies are best known as suppliers of spacecraft components and engineering services, although DSS has also developed a robotic lunar lander and is part of NASA’s Commercial Lunar Payload Services program.

“What we wanted to do with Redwire is take some of the traditional space heritage from the small, agile and innovative companies out there like Adcole and DSS and combine them with a true innovator,” said Peter Cannito, chief executive of Redwire, in an interview.

Made In Space, he argued, is that innovator. “The things that they’re doing are things that have never been done and really have the potential to change the economics of space,” he said. “That filled a key gap in our strategy.”

Though the companies under Redwire will for now operate separately, eventually they will combine under the Redwire name. Note too that the head of Made in Space is now the CEO of Redwire while its chief engineer is now Redwire’s chief technology officier, so this acquisition appears more like a partnership between companies that helps them all, rather than an acquisition.

Leave a comment

We are one step closer to the first replicator

10:01 am

Scientists have developed and tested a 3D printing technique that quickly creates entire objects as a unit, rather than building them by layers.

Here’s how it works. First, the researchers use a computer-controlled digital light projector to cast a series of 2D images through a rotating vial containing a photosensitive gel. As the vial rotates, photons entering from different angles meet at selected spots in the gel. Where they meet, their combined energy solidifies the gel. Where that meetup doesn’t occur, the photons simply pass through without altering the photosensitive material.

The approach is fast, able to create complex objects, such as a centimeter-size copy of Rodin’s famous sculpture of The Thinker in just minutes, the researchers report today in Science. It can also make 3D plastic parts around existing objects, such as a plastic handle around a metallic screwdriver shaft. The approach could also be useful for encapsulating sensitive electronics, the authors write.

If you go to the supplementary material for their paper, you can watch several videos showing this process at work, creating both the Thinker as well as a ball in a cage.

I think I have reported on this process previously, but this new paper shows a significant advance. Nonetheless, this engineering here is still very preliminary.

2 comments

3D printed screws from fake moon dust

10:11 am

Researchers in Europe have successfully printed screws and gears using simulated moon dust.

These printed materials weren’t carbon-based plastic or metal, according to a statement from the ESA, but rather a sort of lunar ceramic. “Ground and sieved down to particle size, the regolith grains are mixed with a light-reacting binding agent, laid down layer-by-layer, then hardened by exposing them to light,” according to the statement. “The resulting printed part is then sintered in an oven to bake it solid.”

In other words, all these little gadgets had production histories closer to the dinner plate in your cupboard than the screws holding that cupboard together.

This is still an experimental project, so there’s a lot more testing to be done — including whether these parts are strong enough to stand up to the stresses of real-world use.

They might find these parts aren’t hard enough for their use as screws and gears, but finding a way to produce these parts in space rather than having them shipped from Earth will be essential for making any future space colony viable.

3 comments

HP to mass produce large 3D metal printers

9:18 am

The replicators are coming! HP has announced that it plans to mass produce a large 3D metal printer that can be used by large industrial manufacturers.

Each Metal Jet production machine will cost less than US$400,000, and will give you a maximum build volume of 430 x 320 x 200 mm (16.9 x 12.6 x 7.9 inches).

HP is timetabling the Metal Jet roadmap in stages. Right now, it’s already operational in two pilot programs. Metal injection molding specialist Parmatech is using it to produce medical equipment like surgical scissors and endoscopic surgical jaws, and GKN Powder Metallurgy is producing parts for automotive and industrial giants like Volkswagen and Wilo.

In 2019, HP will start up a production service, which will allow manufacturers to upload 3D design files and have them printed out in industrial quantities by Parmatech and GKN. The printers themselves will begin shipping in 2020, with “broad availability in 2021.” Desktop Metal, for its part, has pushed back availability of its production machines from this year to 2019.

HP is not the first to do this, but this appears to be the largest-scale production attempt.

Leave a comment

Inventor of 3D gun wins lawsuit against Justice

5:14 pm

The inventor of a 3D gun has won a free speech lawsuit against the Justice Department for its order blocking the publication of his 3D gun designs.

Cody Wilson’s Defense Distributed and Second Amendment Foundation (SAF) reached a settlement with the Department of Justice allowing unfettered publication of 3D gun files and other information in a case centered on free speech. Breitbart News reported that SAF filed a suit on behalf of Defense Distributed on May 6, 2015, seeking to free Wilson from a federal mandate that he not post blueprints for The Liberator pistol online.

Over three years later, the announcement comes that Wilson and SAF won. SAF sent a press release to Breitbart News, explaining details of settlement, saying, “The government has agreed to waive its prior restraint against the plaintiffs, allowing them to freely publish the 3-D files and other information at issue. The government has also agreed to pay a significant portion of the plaintiffs’ attorney’s fees, and to return $10,000 in State Department registration dues paid by Defense Distributed as a result of the prior restraint.”

In other words, the Justice Department had no authority under the Constitution to block the publication of these 3D gun plans, and in its effort to try it has lost badly.

What this really means is that it is now literally impossible for any government to impose gun control. If you want a gun, all you will need is the right kind of 3D printer (getting better all the time) and the right plans, soon to be available on the web. While this might make guns more available for bad guys, I guarantee that they will quickly be outnumbered by the good guys.

6 comments

New method to 3D print entire objects simultaneously, without layering

10:56 am

Life imitates science fiction: Engineers at Lawrence Livermore Lab have developed a new 3D method that creates entire objects in one piece instead of building them up with layering.

Developed by LLNL in collaboration with UC Berkeley, the University of Rochester, and MIT, volumetric printing replaces layering with a process that creates the entire object simultaneously. It does this by using three overlapping lasers beamed in a hologram-like pattern into a transparent tank filled with photosetting plastic resin. A short exposure by a single beam isn’t enough to cure the resin in a short time, but combining three lasers can induce curing in about ten seconds. After the object is formed, the excess resin is then drained off to reveal the complete unit.

“The fact that you can do fully 3D parts all in one step really does overcome an important problem in additive manufacturing,” says LLNL researcher Maxim Shusteff. “We’re trying to print a 3D shape all at the same time. The real aim of this paper was to ask, ‘Can we make arbitrary 3D shapes all at once, instead of putting the parts together gradually layer by layer?’ It turns out we can.”

Volumetric printing is not only faster, but eliminates the need for temporary support structures, is more flexible, and provides more geometric flexibility. So far, it’s been used to create squares, beams, planes, struts at arbitrary angles, lattices, and complex, curved objects.

The process still has problems, as the article describes. Nonetheless, this is just one more step in the invention process that is making a Star Trek replicator possible.

Hat tip reader Mike Buford.

6 comments

3D printing and how it will change what things look like

9:29 pm

Link here. The article not only outlines some of the newer developments in 3D printing, it gives a nice look at how that technology is literally going to change what the things it builds look like.

Simple shapes are popular in human designs because they’re easy. Easy to design, especially with CAD, and easy to manufacture in a world where manufacturing means taking a big block or sheet of something, and machining a shape out of it, or pouring metals into a mold.

But manufacturing is starting to undergo a revolutionary change as 3D printing moves toward commercially competitive speeds and costs. And where traditional manufacturing incentivizes the simplest shapes, additive manufacturing is at its fastest and cheapest when you use the least possible material for the job. That’s a really difficult way for a human to design – but fairly easy, as it turns out, for a computer. And super easy for a giant network of computers.

The result: a stronger object, less weight, and less cost.

One comment

3D printing of bricks, using moondust

8:45 am

European engineers have managed to print bricks using simulated moondust and focused sunlight.

The resulting bricks have the equivalent strength of gypsum, and are set to undergo detailed mechanical testing. Some bricks show some warping at the edges, Advenit adds, because their edges cool faster than the centre: “We’re looking how to manage this effect, perhaps by occasionally accelerating the printing speed so that less heat accumulates within the brick. But for now this project is a proof of concept, showing that such a lunar construction method is indeed feasible.”

The video at the link is very unconvincing. While it shows film of the printing process, it does not show film of anyone holding or manipulating the finished bricks. Instead, it shows one or two photos of finished bricks, all of which give the impression that these bricks crumble easily at the edges, I suspect that the bricks are simply too fragile for practical use.

So, is this a proof of concept? Maybe. They have at least shown that 3D printing using materials on the Moon might work.

24 comments

World record for largest 3D printed object

8:59 am

Oak Ridge National Laboratory has entered the Guinness record books with the successful printing of the world’s largest 3D printed object.

Made from carbon fiber and ABS thermoplastic composite materials, the new tool measures 17.5 x 5.5 x 1.5 ft (5.3 x 1.7 x 0.5 m) and weighs around 1,650 lb (748 kg). To meet the requirements of the record, the item needed to be one solid piece of 10.6 cubic ft (0.3 cubic m), which a Guinness World Records judge confirmed at a ceremony. “The recognition by Guinness World Records draws attention to the advances we’re making in large-scale additive manufacturing composites research,” says Vlastimil Kunc, leader of [Oak Ridge] team. “Using 3D printing, we could design the tool with less material and without compromising its function.”

Of course, the tool wasn’t designed just for world record glory: printable in just 30 hours, it’s an impressive time and cost saver, considering the existing metal version currently takes about three months to manufacture. [emphasis mine]

The highlighted text illustrates in one sentence why there is a push toward 3D printing. It is cheaper, faster, and will eventually provide much greater flexibility.

One comment

A toy replicator for kids!

10:00 am

Mattel is bringing back an old toy, Thingmaker, but the new version will be a 3D printer for kids.

After wirelessly linking the 3D printer to a mobile device running the ThingMaker Design App for iOS or Android, users decide whether they want to create a toy figure or jewelry, with the option to print ready-designed toys, or mix and match from hundreds of parts which can be popped together after printing thanks to ball and socket joints. After designing their creation, users simply push a button to start printing.

Features of the ThingMaker 3D printer which make it more suitable for children than your typical 3D printer include it being simple to use, and having an auto-locking door. This will stay shut until your toy is at a safe temperature and the hot print head has retracted into a recess, so that it can’t burn eager little fingers.

Simplicity is applicable to adults as well. This gives us a hint where all 3D printing is heading.

And though the article describes as a negative the fact that it will routinely take 12 hours for each toy to print, I consider this irrelevant. I would have loved to have this thing as a kid, and would have gladly tried out a new design each day, just for fun. The toys themselves are what is irrelevant, not the creation process.

5 comments

The UK launches a 3D printed airplane drone

10:01 am

A University of Southampton team, under a project for the Royal Navy of the United Kingdom, have built and launched an entirely 3D printed unmanned air vehicle (UAV) from a navy ship.

Produced under the institution’s Project Triangle, the Southampton University Laser Sintered Aircraft (SULSA) UAV was launched via catapult from the patrol vessel HMS Mersey, and flew over the Wyke Regis training facility near Weymouth in the south of the country to land on Chesil beach. The 5min sortie covered a range of some 500m, with the UAV carrying a small video payload to record the mission so that operators could monitor it during the flight.

SULSA measures 150cm (59in) and weighs 3kg (6.6lb), and is made via 3D printing using laser sintered nylon. The university claims that SULSA is the world’s first UAV made entirely via the technique. It consists of four separately manufactured main parts that are assembled without the need for any additional tools.

The specific achievement here is interesting, but its significance in illustrating the growing use of unmanned drones and 3D printing is more important. Very soon, a large percentage of everything we own will be built with 3D printing technology, lowering the cost while making construction easier. As for drones, they carry both positive and negative possibilities.

Leave a comment

3D printed items made in space come back to Earth

11:00 pm

NASA today released a video of engineers unpacking a box of 3D parts that had been printed on ISS and then returned to Earth for testing.

Some more details here.

The goal, Bean continued, is for NASA to develop a database of mechanical properties to see if there’s any difference in mechanical strength between identical items made in space and on Earth. During the interview last month, Bean said that while NASA didn’t yet have any hard data, there had been initial indications from videos made on the space station, that the plastics used in the 3D printing there had “adhered differently” than those in the terrestrial test. “The astronauts trying to get the parts off the plate,” Bean said, found that the plastic “seemed to be a little more stuck than on the ground.” He said that while it was too early to tell if that was actually true, his guess was that if so, “it may be due to a lack of convection in zero-gravity.”

Understanding the engineering issues of 3D printing in space will make it possible for crews to carry far less cargo on long interplanetary journeys. Instead, they would carry a much smaller amount of raw material, which they could use to manufacture items as needed, then recycled.

One comment

First 3D part manufactured in space

11:07 pm

Astronauts on ISS have used a 3D printer, shipped to the station on the last Dragon flight, to print the first item ever manufactured in space.

“Everything worked exactly as planned, maybe a little better than planned,” Kemmer told NBC News. He said only two calibration passes were needed in advance of the first honest-to-goodness print job, which finished up at 4:28 p.m. ET Monday and was pulled out of the box early Tuesday. “It’s not only the first part printed in space, it’s really the first object truly manufactured off planet Earth,” Kemmer said. “Where there was not an object before, we essentially ‘teleported’ an object by sending the bits and having it made on the printer. It’s a big milestone, not only for NASA and Made In Space, but for humanity as a whole.”

The part made was a faceplate for the printer itself. This printer is a demonstration project, launched to test the engineering and to see how 3D printing operates in weightlessness. Eventually the goal is to have most of the spare parts on a interplanetary vehicle manufactured in space in this manner, using a supply of standard material, called feedstock, that would be much cheaper to ship from Earth.

Leave a comment

Amazon’s 3D printshop opens

9:20 am

The competition heats up: Amazon has opened its first 3D-print shop, where customers can buy 3D printed products.

The store has launched with more than 200 print-on-demand designs. Users can customize items like earrings, pendants, rings and bobble head dolls using a special widget, before having the item 3D-printed and delivered. …

Although users of the store cannot upload and print their own designs, it is, as mentioned, possible to customize some of the available designs. Amazon has built a customization engine into the store, allowing for very simple changes to an item’s design, or more wholesale changes. Interactive 3D preview functionality is also provided, with which users can rotate an object and view it from any angle.

What does this story have to do with space exploration? Well, it marks the beginning of a major revolution in manufacturing that will change everything. And since 3D printing is going to be an essential need for future space explorers, having this new industry prosper and grow can only speed up the exploration and settlement of the solar system.

2 comments

A Texas-based company has printed the first 3D-printed metal pistol, a 45 caliber Model 1911.

8:57 am

A Texas-based company has printed the first 3D-printed metal pistol, a 45 caliber Model 1911.

Video below the fold. The gun clearly functions, though I noticed that in the video they never loaded more three rounds in a magazine, and that the gun seems to cycle weakly. I suspect that they had some feeding problems when they tried to fire a full loaded five round magazine.

Nonetheless, this achievement further illustrates that 3D printing is about to become a major method of manufacture.
» Read more

3 comments

A 3D printer intended for installation on ISS in 2014 has successfully proven it can work in weightlessness.

9:12 pm

A 3D printer intended for installation on ISS in 2014 has successfully proven it can work in weightlessness.

Three prototype versions of space manufacturing startup Made in Space’s 3D printer showed their stuff during four airplane flights that achieved brief periods of microgravity via parabolic maneuvers, company officials announced today (June 19).

Then there’s this:

“The 3D printer we’re developing for the ISS is all about enabling astronauts today to be less dependent on Earth,” Noah Paul-Gin, Made in Space’s microgravity experiment lead, said in a statement. “The version that will arrive on the ISS next year has the capability of building an estimated 30 percent of the spare parts on the station, as well as various objects such as specialty tools and experiment upgrades.” [emphasis mine]

If this claim is true, this printer will do a lot to make interplanetary space travel far more likely. It will mean that travelers far from home will be able to manufacture the spare parts they need, on demand, should something break. This will save a lot of weight, compared to carrying pre-made spare parts.

8 comments

Video of a successful test firing of Liberator, the first working 3D printed gun.

8:37 am

Video of a successful test firing of Liberator, the first working 3D printed gun.

Not surprisingly, the Democrats in Congress are rushing to outlaw this weapon, as is their typical approach to anything they don’t like: outlaw it, ban it, prohibit it, control it, restrict it.

In other related news, a news paper editor in Colorado has decided that the only fair way to debate the NRA is to send every member of the organization to prison.

No more due process in the clear-cut case of insidious terrorism. When the facts are so clearly before all Americans, for the whole world to see, why bother with this country’s odious and cumbersome system of justice? Send the guilty monsters directly to Guantanamo Bay for all eternity and let them rot in their own mental squalor.

No, no, no. Not the wannabe sick kid who blew up the Boston marathon or the freak that’s mailing ricin-laced letters to the president. I’m talking about the real terrorist threat here in America: the National Rifle Association. [emphasis mine]

Our modern liberal community: Restrict freedom, dump due process, imprison your opponents.

32 comments
1 2