Bailet, Gilles

Deans, M.

McInnes, C.R.

Patterson, Charlie

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Space and Exploration Technology GroupQualification of additive manufacturing for space and in-space materials and processes- NextSpace Testrig -Gilles Bailet, M. Deans, and C. R. McInnesThe NextSpace Testrig project was supported by the UK Space Agency under the Enabling Technology Program 3. GB and CM were also supported by the Royal Academy of Engineering under the Chair in Emerging Technologies program.The authors wish to acknowledge the Manufacturing Technology Centre for being partners on the NextSpace Testrig project.Space and Exploration Technology Group2gilles.bailet@glasgow.ac.ukAdditive manufacturing in the space sector21/02/2021Optimised 3d printed bracket(credit: Thales Alenia Space) Nylon PA12+CF CubeSat structure (credit: Windform, Windform® XT 2.0) 3d printing of a rocket engine (credit: Skyrora) PEEK CubeSat structure (credit: ORION-AM) Space and Exploration Technology Group3gilles.bailet@glasgow.ac.ukAdditive manufacturing in the space sector21/02/2021Optimised 3d printed bracket(credit: Thales Alenia Space) Nylon PA12+CF CubeSat structure (credit: Windform, Windform® XT 2.0) 3d printing of a rocket engine (credit: Skyrora) PEEK CubeSat structure (credit: ORION-AM) Let’s look at additive manufacturing of polymersSpace and Exploration Technology Group4gilles.bailet@glasgow.ac.ukAdditive manufacturing: stepping toward the future21/02/2021Archinaut-1 mission demonstrator3d printed 10m beam (credit: RedWire) CASSIOPeIAKm-scale space based solar power(credit: Space Solar) 3d printing of full systems in spaceActive antenna manufacturing(credit: UofG spin-out) Space and Exploration Technology Group5gilles.bailet@glasgow.ac.ukAdditive manufacturing: a miracle solution?21/02/2021Openart.iaPrompt: a satellite split in thirds in the middle because of the structure is flying away, flying over the stars, with a very long truss with a big space in the middle attached to the side of the earth, separated in the middle, Felix-Kelly, space art, ue 5, a computer rendering.Without proper quality insurance, oversight, regulation and new standards, this miracle solution breaking the constraints of rocket launchers could open up Pandora’s box and accelerate the forthcoming Kessler syndrome Space and Exploration Technology Group6gilles.bailet@glasgow.ac.ukNylon PA12 as a first example21/02/2021Nylon as other polymers is hygroscopic:Ø NASA low Total Mass Loss is 0.29-3.40% for 24hØ Total absorption is up to 10+%Ø Water Vapor Regain is 4% for 24h at 50% RHØ PA12 is now widely used in the space industry up to the point that it is core to many CubeSat structures Effects of Moisture Absorption on Nylon parts(credit: Intech Corporation 2014)Space and Exploration Technology Group7gilles.bailet@glasgow.ac.ukNylon PA12 as a first example21/02/2021Discrepancy between material properties and testing protocols§ Even for NASA/ESA ECSS approved materials, water vapor regain (WVR) can decrease performances by >10%.§ What about performances at extreme of temperatures? current standards characterise properties at 25oCEffects of Moisture Absorption on Nylon parts(credit: Intech Corporation 2014)Space and Exploration Technology Group8gilles.bailet@glasgow.ac.ukWhat about other polymers?21/02/2021PEEK sample @10% infill (von Misesmax=1.729 MPa)PEEK sample @30% infill(von Misesmax=1.343 MPa) PEEK sample w/ 1mm3 internal defect(von Misesmax=0.347 MPa) Effect of internal cavities, the limits of infill and NDT; ex. FDM PEEK tensile strength = 87.6 MPaSpace and Exploration Technology Group9gilles.bailet@glasgow.ac.ukWhat does the space segment needs?- our thoughts -21/02/2021Pain point:§ Current standards do not allow to account for the complexity of AM for use in space.§ What about AM parts created ex nihilo in space?Solution:Ø Rethink the way we approach AM material and processes testing and qualification.Ø Listen to the use cases of the space community. (that’s why we are here)Space and Exploration Technology Group10gilles.bailet@glasgow.ac.ukNextSpace Testrig§ Project funded by the UK Space Agency.§ University of Glasgow (PI), the Manufacturing Technology Center (Co-I).§ End-user partners: Thales Alenia Space UK, Skyrora, In-Space Missions, AVS.§ …join us to identify the needs of the community.Project PartnersEnd-users21/02/2021Space and Exploration Technology Group11gilles.bailet@glasgow.ac.ukNextSpace TestrigObjectives§ Deliver a novel universal test machine and associated novel technologies able to characterize and qualify 3d printed materials and processes in a simulated space environment. § Engage end-users to maximize space sector impact.§ Provide datasets to assess policy changes needed.21/02/2021Space and Exploration Technology Group12gilles.bailet@glasgow.ac.ukRequirementsUniversal Test Machine (UTM) requirements§ Able to swap jaws to different test types (see table)§ Test plastics and metals [1]§ Simulated Space Environment• High-Vacuum, 10-3 Pa [2]• Thermal cycling, 200°C to -100°C (392 °F to -148 °F)  § Automation (in consideration)• Increase throughput of system• Multiple tests without cycling vacuum chamberTest Types MaterialsTensile MetalsCompressive Thermoplastics3-point bending ElastomersShear CeramicsImpactFrictionTearPeel[1] ISO 527, ‘Plastics — Determination of tensile properties’, 2019[2] ASTM E595, Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment, 202121/02/2021Space and Exploration Technology Group13gilles.bailet@glasgow.ac.ukTest sample geometry 21/02/2021Thickness = 3mm to 9mm (1/8’’ to 23/64”)Figure 1: Tensile specimen design[3] Bergonzi, L., Vettori, M. and Pirondi, A. (2019) ‘Development of a miniaturized specimen to perform uniaxial tensile tests on high performance materials’, Procedia Structural Integrity, 24, pp. 213–224. doi:10.1016/j.prostr.2020.02.018. § Modified dog bone tensile specimen [3]§ Force translated through shoulders• Compact• Enables future automationSpace and Exploration Technology Group14gilles.bailet@glasgow.ac.ukTestrig design21/02/2021NextSpace Testrig mounted in vacuum chamberNextSpace Testrig schematic of key componentsLoad FrameCrossheadTest fixtures (Jaws)Load cellMotorsTest specimenSpace and Exploration Technology Group15gilles.bailet@glasgow.ac.ukPreliminary resultsØ Mechanical performances reduced by 9.8%21/02/2021Tensile strain at fracture of Nylon PA12 sample in vacuum and non-vacuumFracture Strain (%)Test No.Non-VacuumVacuum1 14.64 15.672 17.49 17.443 19.83 16.634 18.88 14.345 17.26 15.39Avg. 17.62± 1.7615.89± 1.06Space and Exploration Technology Group16gilles.bailet@glasgow.ac.ukLooking forwardProgram developmentØ Include Ultra High Vacuum capabilityØ Include liquid nitrogen cooling in the jawsØ Include infrared/induction heatingØ Investigate high resolution Direct Image Correlation 21/02/2021Space and Exploration Technology GroupThank you for your attentionThank you for your attention@SpaceGlasgowgilles.bailet@glasgow.ac.ukSome more details at Matthew Deans poster tonightCome build a safer and more reliable in-space manufacturing future

Qualification of additive manufacturing for space and in-space materials and processes - NextSpace Testrig

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Qualification of additive manufacturing for space and in-space materials and processes - NextSpace Testrig

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