Exploring AM in Space: Insights from Experts on the Additive Snack Podcast

september 5, 2024 | Reading time: 10 min

In this episode of the Additive Snack Podcast, Host Fabian Alefeld and his guests take you where no man has gone before - a fascinating discussion with some of the brightest minds in the additive manufacturing (AM) and the space exploration industries.

Joining him were… 

●    Paul Gradl, Principal Engineer at NASA
●    Eliana Fu, Industry Manager for Aerospace and Medical at TRUMPF
●    Myles Keefer, Manager of Additive Manufacturing at Rocket Lab. 
●    Advenit Makaya, Advanced Manufacturing Engineer at the European Space Research and Technology Centre of the European Space Agency

The current state and successes of AM in space
Myles Keefer opened the dialogue by providing an overview of the current state of industrial 3D printing in space. Keefer emphasized how AM is critical for the space industry, especially through technologies like laser powder bed fusion and directed energy deposition (DED).

These technologies expedite the iterative process, allowing companies to rapidly prototype and test components, a necessity given the high stakes and costly nature of space exploration. Keefer also pointed out that the industry's shift toward part consolidation and geometric freedom showcases the unmatched potential of AM in reducing the complexities of the supply chain.

Eliana Fu further expanded on this by bringing her extensive experience from various space organizations. She highlighted how small parts like satellite thrusters and complex structures like engine parts are now routinely being manufactured using laser-based processes.

Large structures that don't fit inside traditional powder bed machines are now being tackled through techniques like wire arc additive manufacturing (WAAM) and DED.

Advancements in AM materials 
A significant part of the episode focused on the innovations in materials for AM. 

Paul Gradl shared his excitement about the novel materials developed specifically for AM, moving beyond traditional materials like aluminum and titanium. He highlighted NASA's use of custom-developed materials like GRX-810 and NASA-HR-1, which show superior performance in extreme environments. These materials, designed for high pressures, temperatures, and challenging chemical environments, are crucial for the future of space missions.

Eliana Fu added to this by illustrating how historical challenges with materials like C103, which were expensive and cumbersome to process traditionally, are now being resolved through AM. Moreover, high-strength aluminum variants and gamma titanium aluminides are now printable, enabling new possibilities in design and application.

Advenit Makaya talked about the European perspective and how Europe is catching up in terms of AM innovation. He pointed out that the ongoing development of integrated computational materials engineering (ICME) and machine learning tools offers unprecedented possibilities for material science, allowing the creation of entirely new alloys tailored for the specific requirements of space exploration.

Challenges and prospects in AM for space
Despite the advancements, the industry still faces significant challenges. According to Paul Gradl, the post-processing steps remain a bottleneck. While building parts might be quick, subsequent processes like depowdering, electrical discharge machining (EDM) cut-off, and heat treatments can delay the overall manufacturing cycle. This is where the industry needs further innovation and efficiency improvements.

Additionally, ensuring the safety and reliability of these newly developed parts is crucial. Gradl emphasized the importance of understanding the AM process intricately, from thermal simulations to sensitivity analysis, to ensure parts are both high-quality and safe. This understanding is necessary to foster confidence among stakeholders, who might still rely on traditional manufacturing for critical components.

Myles Keefer touched on the industry’s outlook from a manufacturer's perspective. At Rocket Lab, the focus is on maximizing machine utilization to meet the accelerated launch schedules. Keefer stressed the need for a balance between iterative development and efficient production to keep pace with the rapidly expanding space industry.

Collaborative efforts and ecosystem building
The discussion also underscored the importance of collaboration within the AM community. The experts agreed that a cooperative approach could foster standardization and shared best practices. Paul Gradl remarked on how the additive community is uniquely collaborative compared to other sectors. Conferences and workshops serve as vital touchpoints where industry leaders and researchers can exchange ideas and solutions.

Eliana Fu commended the collaborative committees like ASTM F42 and SAE, working on creating standardized processes for AM, like those available for traditional materials. This effort is crucial in making AM a mainstream manufacturing process that can be trusted for critical applications.

Inspiring the next generation
No conversation about the future of an industry is complete without discussing education and community outreach. Paul Gradl highlighted NASA's commitment to inspiring the next generation of engineers and scientists through educational programs and hands-on experiences. Engaging students from elementary through university levels in AM-related projects can pave the way for future innovations and ensure a skilled workforce ready to tackle tomorrow’s challenges.

Conclusion
The episode on AM in space is a testament to the incredible journey technology has undertaken and its future potential. From material innovation to process optimization and collaborative efforts, the field of AM in space is poised for significant growth and breakthroughs. By fostering education and maintaining a collaborative spirit, industry can overcome existing challenges and continue to push the boundaries of what is possible.

To dive deeper into these insights, be sure to listen to the full episode of the Additive Snack Podcast. Stay tuned for more engaging discussions with industry leaders who are shaping the future of AM and space exploration.

Check out our guests’ work here: 
Paul Gradl
●    Follow Paul on LinkedIn
●    Check out Paul’s latest work at NASA
●    Find his research on ResearchGate

Eliana Fu
●    Follow Eliana on LinkedIn
●    Find her research on ResearchGate

Myles Keefer
●    Follow Myles on LinkedIn

Advenit Makaya
●    Find his research on ResearchGate
●    Follow Advenit on LinkedIn
●    Check out Advenit’s work for the European Space Agency