China-Australia high-temperature FFF technology demonstrates new potential for in-orbit maintenance of satellites in space

Guide: In the past seventy years, the number of satellites in earth orbit has increased dramatically. It is said that there are now more than 2500 satellites straddling the atmosphere of our planet. Once the equipment in the extraterrestrial space fails, their maintenance will undoubtedly be a costly and major project.

December 10, 2021
Engineers from the National University of Science and Technology and the University of Sydney jointly designed a3D printingThe machine is capable of high temperature processing of PEEK materials under simulated space conditions.
According to the team, using
FDM
3D printing, It is possible to produce PEEK satellite spare parts in orbit, but insufficient heat conduction in space will cause the current system to overheat.To overcome this problem, researchers have developed a new type3D printer, It has a proportional integral (PI) controller that can operate at a high temperature of up to 400°C in a vacuum, which may make it an ideal choice for future track maintenance tasks.

△ Schematic diagram of the 3D printing system for the track proposed by the researchers. Picture from “Advances in Space Research” magazine.

The problem of satellite service?

In addition to the normal operation of satellites can guide space missions, they are also very important for communication and navigation on the earth. Therefore, once a failure occurs, they may deviate from the orbit and generate debris, which may damage the orbiter.Theoretically, the in-orbit manufacturing of satellites will greatly reduce the occurrence of satellite failures, and this method is cheaper than launching rockets full of maintenance equipment into orbit. It is reported that companies such as Northrop Grumman and DARPA are now conducting satellite launch missions. In these missions, their respective “extended aircraft” and “robot aircraft” will also undergo orbital tests.

However, researchers from China and Australia said that by 2030, the cost of on-orbit manufacturing will still soar to US$6.2 billion.To helpaviationaerospaceThe company reduces expenditures in this area. The research team pays special attention to the success of the 3D printing experiment on the International Space Station and suggests that the technology can be deployed in outer space and on manned spacecraft.

Engineers particularly believe that FDM machines may be ideal for track repairs because they do not have lasers, rely on filaments that are easy to store, and are compatible with sturdy materials such as PEEK. However, despite their optimism about the technology, the team admitted that the current system is prone to material clogging in space due to excessive filament melting.

Delta track3D printerThe center tube (pictured) is designed to prevent high temperature blockage. The picture comes from the “Space Research Progress” magazine.

Printing in the vacuum of space

In order to make orbital 3D printing more feasible, the researchers set out to develop a 3D printing system with an upgraded thermal control device that can land on a satellite and then use a robotic arm to replace damaged parts.In addition to these arms and its landing gear, the team’s first prototype was largely based on astandardThe FDM structure is equipped with heating module, sink, roller belt, extruder and radiator.

In order to evaluate its potential before building the machine, the team chose to perform some simulations of PEEK printing. Interestingly, the results show that increasing the number of heat sinks between the heat sink of the device and the radiator can more effectively control the temperature of its core tube, and at the same time prevent the melted filaments from flowing back when the material is fed.

Through simulation, engineers also found that printing under reduced gravity will cause the material to adhere to the inner tube of the system, increase friction, and may cause squeeze and blockage. In order to solve this problem, the team repeatedly modified this part, and then proposed a design to improve its heat transfer efficiency and work at temperatures as high as 400°C.

Finally, after collating all the data, the researchers designed a mathematical model to prove the benefits of introducing the “fuzzy PI control module” to their system. Essentially, the device is designed to start at a temperature of 380°C, which improves the accuracy of its thermal control function, but also prevents the risk of overheating and maintenance errors.

After completing the evaluation, the engineers are now building a working prototype, and they intend to test it in a physical vacuum chamber. In the future, if their printer can find an end use, the team believes that it can help reduce the cost and time of space exploration. Once the satellite fails, it only needs to be repaired in orbit without the need for additional rocket launches.

△Redwire has now installed several 3D printing equipment on the International Space Station, including its Thunderstone printing facility (pictured). Picture from Redwire.

The huge application potential of AM in space orbit

Space 3D printing may sound like something from science fiction, but this technology has been tested in extraterrestrial space on NASA’s International Space Station before.Currently, one of the leaders in this field is Made InSpace, which is now a subsidiary of Redwire. Last year they installed a new one on the orbital base.ceramics3D printing module.

In addition, Made In Space’s technology will also be applied to Blue Origin and Sierra Space’s upcoming commercial “orbital reef” space station. The new base is expected to be launched in 2026 as a mixed-use business park, while continuing to provide test sites for microgravity R&D and experimental production for “manufacturing in space”.

At the same time, at the Munich University of Applied Sciences, researchers took a similar approach to the Chinese-Australian team and developed an orbiting satellite 3D printer. The system is designed to reduce the amount of fuel required to launch maintenance equipment into space, which limits the length of the mission. In the future, the entire solar panel or antenna-related components can be built under zero gravity conditions.

The researchers’ findings are detailed in their paper, entitled “Extrusion and Thermal Control Design of an On-orbit 3D Printing Platform”, which was co-authored by Jianning Tang, Trevor Hocksun Kwan, and Wu Xiaofeng.

Links to related papers:https://www.sciencedirect.com/sc … i/S0273117721008784

(Editor in charge: admin)

China-Australia high-temperature FFF technology demonstrates new potential for in-orbit maintenance of satellites in space

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