{"id":31241,"date":"2018-11-13T13:15:01","date_gmt":"2018-11-13T18:15:01","guid":{"rendered":"https:\/\/digital.hbs.edu\/platform-rctom\/submission\/additive-manufacturing-for-the-final-frontier-how-3d-printing-can-take-us-to-mars-and-beyond\/"},"modified":"2018-11-13T13:15:01","modified_gmt":"2018-11-13T18:15:01","slug":"additive-manufacturing-for-the-final-frontier-how-3d-printing-can-take-us-to-mars-and-beyond","status":"publish","type":"hck-submission","link":"https:\/\/d3.harvard.edu\/platform-rctom\/submission\/additive-manufacturing-for-the-final-frontier-how-3d-printing-can-take-us-to-mars-and-beyond\/","title":{"rendered":"Additive Manufacturing for The Final Frontier: How 3D Printing Can Take Us to Mars (and Beyond)"},"content":{"rendered":"

Context and Challenges<\/strong><\/p>\n

NASA has committed to sending humans to Mars within the upcoming decades.[1]<\/a> \u00a0This is the next step toward the organization\u2019s long-term goal \u201cto expand permanent human presence beyond low-Earth Orbit.\u201d[2]<\/a> \u00a0Manned deep space missions will require spacecraft to be self-sufficient for months, even years at a time.<\/p>\n

To meet these ambitious targets, NASA will need cost-effective tools and processes for transport of raw materials and manufacturing equipment, and fabrication of finished goods using materials from Earth and those found in-situ.<\/p>\n

 <\/p>\n

Additive Manufacturing Advantages in Aerospace Processes and Product Development<\/strong><\/p>\n

At approximately $10,000 per pound of payload[3]<\/a>, weight costs are the<\/em> driving factor in aerospace economics.\u00a0 Additive manufacturing is transforming the industry by allowing for complex, weight-optimized, finished parts and high-efficiency usage of raw materials.<\/p>\n

The complex geometries of aerospace components are challenging, expensive, and time-consuming to create using conventional processes.[4]<\/a> \u00a0Additive manufacturing can fabricate the same components more easily, often with fewer parts, thereby reducing set-up, tooling, and assembly costs, and speeding up production.[5]<\/a> In 2013, engineers at NASA\u2019s Marshall Space Flight Center 3D-printed a rocket engine injector in 2 pieces, versus 115 for the traditionally made version[6]<\/a>, lowering the $300,000 standard cost by 80%.[7]<\/a>\u00a0 Critically, additive manufacturing techniques can yield 40-60% weight reduction while maintaining other important physical properties.[8]<\/a> \u00a0Furthermore, traditional subtractive manufacturing wastes the majority of raw material, with only 10% or so remaining in a final part, while additive manufacturing can achieve material efficiencies of 90%.[9]<\/a><\/p>\n

Finally, additive manufacturing offers possibilities for reclaiming unnecessary parts through recycling, further reducing costs. NASA recently partnered with aerospace company Tethers Unlimited to develop the world\u2019s first \u201crefabricator,\u201d capable of converting 3D-printed items back into feedstock and then re-printing new parts.[10]<\/a>\u00a0 The device recently arrived at the International Space Station (ISS), where astronauts will use it to investigate the reusability of 3D-printed material.<\/p>\n

As Chris Singer, director of the Marshall Center Directorate explains, \u201cAdditive manufacturing will improve affordability from design and development to flight and operations, enabling every aspect of sustainable long-term human space exploration.\u201d[11]<\/a><\/p>\n

 <\/p>\n

NASA\u2019s Pursuit of Additive Manufacturing in Aerospace Applications<\/strong><\/p>\n

NASA has been experimenting with additive manufacturing in aerospace applications through internal and external pathways.<\/p>\n

The first 3D printer in space launched to the ISS in September 2014.[12]<\/a> \u00a0After successfully demonstrating the viability of 3D-printing in zero-gravity, the ISS upgraded to permanent additive manufacturing infrastructure in the form of the Additive Manufacturing Facility (AMF).[13]<\/a> \u00a0The AMF \u201callows for immediate repair of essential components, upgrades of existing hardware, installation of new hardware\u2026and the manufacturing capability to support commercial interests.\u201d[14]<\/a><\/p>\n

\"\"<\/a>
Astronaut Barry Wilmore holding a ratchet wrench 3D printed on the ISS.<\/strong>
Source: \u201cSpace Station 3-D Printer Builds Ratchet Wrench To Complete First Phase Of Operations.\u201d Edited by Jennifer Harbaugh, NASA, NASA, 23 Dec. 2014, www.nasa.gov\/mission_pages\/station\/research\/news\/3Dratchet_wrench. 13 November 2018.<\/figcaption><\/figure>\n

Back on Earth, NASA pushes the boundaries of additive manufacturing with ventures like the Low Cost Upper Stage-Class Propulsion Project.\u00a0 The agency employed new metal alloy 3D-printing techniques to construct a combustion chamber, which it will use for various rocket propulsion tests.[15]<\/a><\/p>\n

Through academic connections and the Small Business Technology Transfer and Small Business Innovation Research programs, NASA supports universities and commercial enterprises in prototyping and testing aerospace-focused 3D-printing solutions.[16]<\/a>[17]<\/a><\/sup> An example is the ongoing 3D-Printed Habitat Challenge, a multi-year competition to develop proofs-of-concept for structures that could be 3D-printed on Mars using endogenous materials.[18]<\/a>\u00a0 Recent winners of the contest\u2019s Phase II consisted of American and international architecture and construction firms, a space-tech start-up, and Northwestern University.[19]<\/a><\/p>\n

\"\"<\/a>
One of five winning designs from Phase II of the 3D Printed Habitat Challenge.<\/strong>
Source: \u201cFive Teams Win a Share of $100,000 in 3D-Printed Habitat Competition.\u201d Edited by Jennifer Harbaugh, NASA, NASA, 23 July 2018, www.nasa.gov\/directorates\/spacetech\/centennial_challenges\/3DPHab\/five-teams-win-a-share-of-100000-in-virtual-modeling-stage. 12 November 2018.<\/figcaption><\/figure>\n

In the near-term, NASA will continue to leverage its partnerships with other institutions to parallelize the exploration of additive manufacturing capabilities.<\/p>\n

 <\/p>\n

Recommendations<\/strong><\/p>\n

The brutal environment of outer space exacts a toll on man-made objects.\u00a0 Currently, astronauts put themselves at risk performing space walks in order to assess and fix damages on the ISS, while other structures may not receive repairs at all.\u00a0 NASA could invest in building robots that use additive manufacturing to restore existing structures.\u00a0 They could, for instance, 3D print covers for holes caused by micrometeorites and other space debris.<\/p>\n

More abstractly, NASA should take advantage of the less restrictive nature of additive manufacturing to expand the creativity of their product design process. \u00a0NASA has a history and an image of relying on rigid, regimented thinking and design, while 3D-printing and computational manufacturing offer avenues for more organic, integrated architectures.\u00a0 Additive manufacturing opens the door to constructing single-material components with gradients of physical properties and to generating composite materials with optimized properties.\u00a0 It also \u00a0easily handles novel shapes that would be difficult or impossible to achieve with standard tooling methods.\u00a0\u00a0 By relying on additive manufacturing,\u00a0 NASA engineers can augment their ideation space and feel less constrained by the fabrication process.<\/p>\n

 <\/p>\n

Balancing Innovation and Responsibility<\/strong><\/p>\n

Additive manufacturing has tremendous potential for space exploration, yet also carries more unknowns than traditional manufacturing processes,[20]<\/a> translating to greater risk.<\/p>\n

How can and should NASA maintain its pursuit of innovation in their product development processes as a large federal organization whose core mission revolves around safety critical systems?<\/p>\n

 <\/p>\n

Word Count: 800<\/p>\n

References<\/strong><\/p>\n

[1]<\/a> United States, Office of Inspector General. NASA\u2019S TOP MANAGEMENT AND PERFORMANCE CHALLENGES, NOVEMBER 2017<\/em>. 6 November, 2017, https:\/\/oig.nasa.gov\/reports\/MC-2017.pdf<\/a>. 11 November 2018.<\/p>\n

[2]<\/a> National Aeronautics and Space Administration Authorization Act of 2010. Pub. L. 111- 267. 124 Stat. 2805. 11 Oct 2010. GPO. Web. 11 Nov. 2018.<\/p>\n

[3]<\/a> \u201cAdvanced Space Transportation Program Fact Sheet.\u201d Edited by Brooke Boen,\u00a0NASA, NASA, 12 Apr. 2008, www.nasa.gov\/centers\/marshall\/news\/background\/facts\/astp.html. 11 November 2018<\/a>.<\/p>\n

[4]<\/a> Prater, Tracie. \u201cAdditive Manufacturing: From Rapid Prototyping to Flight.\u201d https:\/\/ntrs.nasa.gov\/archive\/nasa\/casi.ntrs.nasa.gov\/20150006951.pdf<\/a>. Slide 11. 11 November 2018.<\/p>\n

[5]<\/a> \u201cIndustrial 3D Printing of High-Tech Aerospace Components.\u201d\u00a0EOS, EOS, www.eos.info\/aerospace<\/a>. 11 November 2018.<\/p>\n

[6]<\/a> \u201cNASA Tests Limits of 3-D Printing with Powerful Rocket Engine Check.\u201d Edited by Brooke Boen,\u00a0NASA, NASA, 27 Aug. 2013, www.nasa.gov\/exploration\/systems\/sls\/3d-printed-rocket-injector.html<\/a>. 11 November 2018.<\/p>\n

[7]<\/a> Witze, Alexandra. \u201cNASA to Send 3D Printer into Space.\u201d\u00a0Nature, vol. 513, no. 7517, 10 September 2014, pp. 156\u2013156., doi:10.1038\/513156a. 11 November 2018.<\/p>\n

[8]<\/a> \u201cIndustrial 3D Printing of High-Tech Aerospace Components.\u201d<\/p>\n

[9]<\/a> Titomic – Industrial Scale Additive Manufacturing, 3D Printing, Titanium, Innovative, Melbourne, Australia, www.titomic.com\/aviation-space.html<\/a>. 11 November 2018.<\/p>\n

[10]<\/a>\u00a0 \u201cNASA to Demonstrate Refabricator to Recycle, Reuse, Repeat.\u201d Edited by Kristine Rainey,\u00a0NASA, NASA, 28 Aug. 2017, www.nasa.gov\/mission_pages\/centers\/marshall\/images\/refabricator.html<\/a>. 11 November 2018.<\/p>\n

[11]<\/a> \u201c3-D Printed Rocket Parts Rival Traditionally Manufactured Parts.\u201d Edited by Brooke Boen,\u00a0NASA, NASA, 24 July 2013, www.nasa.gov\/exploration\/systems\/sls\/3dprinting.html<\/a>. 12 November 2018.<\/p>\n

[12]<\/a> Prater, Tracie, et al. \u201c3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing and Future Work.\u201d<\/p>\n

https:\/\/ntrs.nasa.gov\/archive\/nasa\/casi.ntrs.nasa.gov\/20160013371.pdf<\/a>. Slide 6. 11 November, 2018.<\/p>\n

[13]<\/a> Snyder, Michael P. \u201cAdditive Manufacturing Facility (Manufacturing Device).\u201d\u00a0NASA, NASA, 19 July 2018, www.nasa.gov\/mission_pages\/station\/research\/experiments\/2198.html<\/a>. 11 November 2018.<\/p>\n

[14]<\/a> Ibid.<\/p>\n

[15]<\/a> \u201cNASA Advances Additive Manufacturing For Rocket Propulsion.\u201d Edited by Lee Mohon,\u00a0NASA<\/em>, NASA, 9 May 2018, www.nasa.gov\/centers\/marshall\/news\/nasa-advances-additive-manufacturing-for-rocket-propulsion.html<\/a>. 11 November 2018.<\/p>\n

[16]<\/a> Bean, Quincy. \u201c3D Printing In Zero-G Technology Demonstration .\u201d\u00a0NASA, NASA, 6 Dec. 2017, www.nasa.gov\/mission_pages\/station\/research\/experiments\/1115.html<\/a>. 11 November 12 2018.<\/p>\n

[17]<\/a> IDTechEx. \u201cImproving Additive Manufacturing for Space Missions.\u201d\u00a03D Printing Progress, IDTechEx, 5 November 2018, www.3dprintingprogress.com\/articles\/15748\/improving-additive-manufacturing-for-space-missions<\/a>. 11 November 2018.<\/p>\n

[18]<\/a> Coldewey, Devin. \u201cNASA’s 3D-Printed Mars Habitat Competition Doles out Prizes to Concept Habs.\u201d\u00a0TechCrunch, TechCrunch, 27 July 2018, www.techcrunch.com\/2018\/07\/27\/nasas-3d-printed-mars-habitat-competition-doles-out-prizes-to-concept-habs\/ . 11 November 2018.<\/p>\n

[19]<\/a> Ayoubi, Ayda. \u201cNASA Awards Five Teams $100,000 in 3D-Printed Habitat Competition.\u201d\u00a0Architectmagazine.com, Architect Magazine, 30 July 2018, www.architectmagazine.com\/technology\/nasa-awards-five-teams-100-000-in-3d-printed-habitat-competition_o<\/a>. 11 November 2018.<\/p>\n

[20]<\/a> Vickers, John. \u201cThe Crucial Role of Additive Manufacturing at NASA.\u201d https:\/\/ntrs.nasa.gov\/archive\/nasa\/casi.ntrs.nasa.gov\/20170000638.pdf<\/a>. Slide 27. 11 November 2018.<\/p>\n","protected":false},"excerpt":{"rendered":"

A look at how NASA is using additive manufacturing on Earth and in orbit to realize the future of space exploration.<\/p>\n","protected":false},"author":11793,"featured_media":31255,"comment_status":"open","ping_status":"closed","template":"","categories":[3340,285,37,1318,4610],"class_list":["post-31241","hck-submission","type-hck-submission","status-publish","has-post-thumbnail","hentry","category-additive-manufacturing","category-aerospace","category-innovation","category-mars","category-space-travel","hck-taxonomy-organization-nasa","hck-taxonomy-industry-aerospace","hck-taxonomy-country-united-states"],"connected_submission_link":"https:\/\/d3.harvard.edu\/platform-rctom\/assignment\/rc-tom-challenge-2018\/","yoast_head":"\nAdditive Manufacturing for The Final Frontier: How 3D Printing Can Take Us to Mars (and Beyond) - Technology and Operations Management<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/d3.harvard.edu\/platform-rctom\/submission\/additive-manufacturing-for-the-final-frontier-how-3d-printing-can-take-us-to-mars-and-beyond\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Additive Manufacturing for The Final Frontier: How 3D Printing Can Take Us to Mars (and Beyond) - 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