Opportunities and challenges in additive manufacturing used in space sector: a comprehensive review

Abstract

Purpose The purpose of this study is to explore the applications of 3D printing in space sectors. The authors have highlighted the potential research gap that can be explored in the current field of study. Three-dimensional (3D) printing is an additive manufacturing technique that uses metallic powder, ceramic or polymers to build simple/complex parts. The parts produced possess good strength, low weight and excellent mechanical properties and are cost-effective. Therefore, efforts have been made to make the adoption of 3D printing successful in space so that complex parts can be manufactured in space. This saves a considerable amount of both time and carrying cost. Thereof the challenges and opportunities that the space sector holds for additive manufacturing is worth reviewing to provide a better insight into further developments and prospects for this technology. Design/methodology/approach The potentiality of 3D printing for the manufacturing of various components under space conditions has been explained. Here, the authors have reviewed the details of manufactured parts used for zero-gravity missions, subjected to onboard international space station conditions and with those manufactured on earth. Followed by the major opportunities in 3D printing in space which include component repair, material characterization, process improvement and process development along with the new designs. The challenges like space conditions, availability of power in space, the infrastructure requirements and the quality control or testing of the items that are being built in space are explained along with their possible mitigation strategies. Findings These components are well comparable with those prepared on earth which enables a massive cost saving. Other than the onboard manufacturing process, numerous other components as well as a complete robot/satellite for outer space applications were manufactured by additive manufacturing. Moreover, these components can be recycled onboard to produce feedstock for the next materials. The parts produced in space are bought back and compared with those built on earth. There is a difference in their nature, i.e. the flight specimen showed a brittle nature, and the ground specimen showed a denser nature. Originality/value This review discusses the advancements of 3D printing in space and provides numerous examples of the applications of 3D printing in space and space applications. This paper is solely dedicated to 3D printing in space. It provides a breakthrough in the literature as a limited amount of literature is available on this topic. This paper aims at highlighting all the challenges that additive manufacturing faces in the space sector and also the future opportunities that await development.

3D printing in space: from mechanical structures to living tissues

“…For instance, during the 1970 Apollo 13 mission, the crew had to resort to the lifeboat due to discrepancies in lithium hydroxide canisters between the Command Module and the Lunar Module. Fast forward to 2013, Made In Space, Inc. promptly engineered a 3D-printed adapter for a similar issue, demonstrating its operational success within a day [15]. This capability enhances mission autonomy and reduces reliance on Earth-bound logistics for unforeseen technical difficulties.…”

Design and Optimization of Thin-Walled Main Support Structure for Space Camera Based on Additive Manufacturing

“…The aerospace additive manufacturing market industry is projected to grow from USD 8.29 billion in 2023 to USD 36.25 billion by 2032, exhibiting a compound annual growth rate of 20.24% during the forecast period [24]. Ishfaq K. et al discussed the application of AM in the space field, and these applications demonstrate the feasibility and benefits of AM technology application in space environments [25]. Ransikarcum K et al conducted a study on the business scope and supply chain scope of AM [26,27].…”

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

“…Although AM offers many benefits such as customization, creative freedom and the ability to print complicated shapes, there are still challenges that need to be addressed (Ngo et al , 2018). One major limitation of AM is that it is not suitable for mass-producing large structures due to the high cost involved (Ishfaq et al , 2022). Additionally, the surface quality of products produced using AM, particularly FDM, is generally lower than those produced using conventional technology.…”