Mass production of spacecraft components is being made possible with the creation of new 3D printing systems that function effectively in weightless environments.
Dr. Gilles Bailet, from Scotland's University of Glasgow, has been granted a patent for a system to implement construction during space travel on a demand basis.
He hopes the technology, which was tested on a zero-gravity research aircraft, could make space exploration more sustainable and reduce space debris.
Dr Bailet stated that his invention, utilizing granular materials, could enable plans for producing equipment in space that cannot be manufactured on Earth.
"As the expense of launching items into space is decreasing, we are observing a significant increase in the number of things being sent into space, and this development is deemed unsustainable," Dr. Bailet stated.
Our intention is to enable on-site fabrication in space via 3D printing technology, which would promote recycling in space and create a comprehensive circular economy.
The International Space Station (ISS) was equipped with its first 3D printer in 2014, and since then, research on producing components in a weightless environment has been ongoing both here on Earth and in orbit.
Dr. Bailet's prototype 3D printer utilizes a particulate material instead of the filaments conventionally used on Earth.
Bearing in mind the challenges posed by weightlessness and a vacuum state in space, the materials can be aspirated from a feedstock tank and conveyed to the printer's nozzle more quickly than alternative methods.
The test took place in November as part of the 85th parabolic flight campaign of the European Space Agency, held at Novespace in Bordeaux, France.
The team took their test kit on three flights, providing them with over 90 brief periods of weightlessness at the peak of steep, rollercoaster-like ascents followed by rapid descents.
He was elated to see his technological creation working flawlessly as designed after conducting tests on the zero gravity aircraft, fondly referred to as the "vomit comet" due to its rollercoaster-like flight pattern, which offers 22 seconds of weightlessness each time it reaches a peak.
Now that we have confirmed our technology can operate in space, we will be able to conduct the first space-based demonstration of our technology in the next stage of our development process.
Dr. Bailet and his colleagues are also undertaking research to integrate electronics into the materials as part of the printing process.
Currently, everything launched into Earth's orbit originates from the planet's surface and is propelled into space using rockets.
They have greatly restricted mass and volumes and can shatter into pieces during launch when physical limits are exceeded, resulting in the loss of valuable cargo in the process.
He noted that products created on Earth can be less robust in the vacuum of space, and 3D printing has only been successfully achieved in the pressurized modules of the International Space Station so far.
While Dr. Bailet's project is currently focused on developing components to improve spacecraft, such as radiators and antennae, the long-term goal is to construct equipment directly in space.
Options may include solar reflectors to generate zero-carbon electricity for transmission back to Earth, enhanced communication antennae, or specialized laboratories for drug research that can develop purer and more effective pharmaceuticals.
_"Crystals grown in space tend to be larger and more well-structured than those developed on Earth, made possible by environmental conditions conducive to growth in space. Consequently, a space-based chemical factory could generate innovative new drugs for subsequent transportation to the surface," he noted._
Dr. Bailet and his team are now seeking financial support to facilitate the first in-orbit demonstration of their technology.