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A gravity-independent powder-based additive manufacturing process tailored for space applications

D'Angelo, Olfa and Kuthe, Felix and Liu, Szu-Jia and Wiedey, Raphael and Bennett, Joe M. and Meisnar, Martina and Barnes, Andrew and Kranz, W. Till and Voigtmann, Thomas and Meyer, Andreas (2021) A gravity-independent powder-based additive manufacturing process tailored for space applications. Additive Manufacturing, p. 102349. Elsevier. doi: 10.1016/j.addma.2021.102349. ISSN 2214-8604.

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Abstract

The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions independently of the gravitational environment and with no restriction on feedstock powder flowability. Based on a specific sequence of boundary loads applied to the granular packing, powder is transported to the printing zone, homogenized and put under compression to increase the density of the final part. The powder deposition process is validated by simulations that show the homogeneity and density of deposition to be insensitive to gravity and cohesion forces within a discrete element method (DEM) model. We further provide an experimental proof of concept of the process by successfully 3D printing parts on-ground and on parabolic flight in weightlessness. Powders exhibiting high and low flowability are used as model feedstock material to demonstrate the versatility of the process, opening the way for additive manufacturing of recycled material.

Item URL in elib:https://elib.dlr.de/144363/
Document Type:Article
Title:A gravity-independent powder-based additive manufacturing process tailored for space applications
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
D'Angelo, Olfaolfa.lopez (at) dlr.deUNSPECIFIED
Kuthe, Felixfelix.kuthe (at) dlr.deUNSPECIFIED
Liu, Szu-JiaUNSPECIFIEDUNSPECIFIED
Wiedey, RaphaelUNSPECIFIEDUNSPECIFIED
Bennett, Joe M.UNSPECIFIEDUNSPECIFIED
Meisnar, MartinaUNSPECIFIEDUNSPECIFIED
Barnes, AndrewESAUNSPECIFIED
Kranz, W. TillUniversität KölnUNSPECIFIED
Voigtmann, ThomasThomas.Voigtmann (at) dlr.deUNSPECIFIED
Meyer, AndreasAndreas.Meyer (at) dlr.deUNSPECIFIED
Date:2021
Journal or Publication Title:Additive Manufacturing
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:Yes
In ISI Web of Science:Yes
DOI :10.1016/j.addma.2021.102349
Page Range:p. 102349
Publisher:Elsevier
ISSN:2214-8604
Status:Published
Keywords:additive manufacturing; 3D printing; granular materials; powder handling; microgravity; weightlessness; parabolic flight experiment
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Space
HGF - Program Themes:Research under Space Conditions
DLR - Research area:Raumfahrt
DLR - Program:R FR - Research under Space Conditions
DLR - Research theme (Project):R - Materials Research and Microgravity (MuM)
Location: Köln-Porz
Institutes and Institutions:Institute of Materials Physics in Space
Deposited By: Voigtmann, Dr.rer.nat. Thomas
Deposited On:11 Oct 2021 08:48
Last Modified:11 Oct 2021 08:48

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