Dr Gilles Bailet, from the University of Glasgow's James Watt School of Engineering, has received a patent for a novel system designed to overcome the technical challenges of 3D printing in zero-gravity environments. This innovation has undergone extensive testing aboard a research aircraft, commonly referred to as the 'vomit comet.'

"Currently, everything that enters Earth's orbit is constructed on the surface and transported into space on rockets, which impose strict limits on mass and volume. Payloads can also suffer damage during launch. By placing manufacturing systems in orbit, we can bypass these constraints, enabling more ambitious and resource-efficient projects," said Dr Bailet.

Dr Bailet's 3D printer prototype uses a specially designed granular material instead of the filament commonly employed by terrestrial 3D printers. This material is optimized to function in microgravity and the vacuum of space, offering consistent performance where conventional systems falter. The printer's material feed mechanism operates faster and more reliably than existing methods.

The research also explores embedding electronics into printed components, unlocking the potential for self-contained, functional devices to be manufactured in space. "Additive manufacturing, or 3D printing, has the potential to revolutionize space missions by enabling in-orbit assembly of equipment tailored to specific tasks, rather than being limited by launch requirements," Dr Bailet added.

The technology's effectiveness was recently demonstrated in microgravity during the 85th European Space Agency parabolic flight campaign, conducted with Novespace in Bordeaux, France. Over three flights, the research team tested their system through 90 periods of weightlessness lasting 22 seconds each. These tests validated the system's performance under microgravity conditions, with precise monitoring of its dynamics and power consumption.

Dr Bailet highlighted potential applications such as creating solar reflectors to generate clean energy for Earth, manufacturing advanced communication antennae, and developing pharmaceutical research stations capable of producing purer and more effective medications. He noted, "For example, insulin crystals grown in space have been shown to be significantly more effective, potentially reducing the frequency of injections for diabetic patients."

Colleague Professor Colin McInnes' SOLSPACE project is also leveraging 3D printing for the development of space-based solar reflectors. These devices could collect solar energy around the clock, contributing to global net-zero emissions targets. "3D-printed reflectors and other components built in space could redefine how we generate and use power," Dr Bailet explained.

As they seek funding for an in-space demonstration, Dr Bailet and his team are also addressing the critical issue of space debris. Supported by the UK Space Agency, their efforts aim to ensure that future manufacturing systems operate sustainably.

Funding for this project has been provided by the University of Glasgow's Glasgow Knowledge Exchange Fund, the EPSRC Impact Acceleration Account, and the RAEng Chair in Emerging Technologies of Professor Colin McInnes, along with a RAEng Proof of Concept award.

Related Links
SOLSPACE project
Space Technology News - Applications and Research