Werkheiser, Niki

NASA Technical Reports Server

Niki Werkheiser
NASA In-space Manufacturing Project Manager
Niki.Werkheiser@nasa.gov
256-544-8406
NASA’s In-space Manufacturing 
(ISM) Overview
Intrepid Sea, Air and Space Museum
July 2016
https://ntrs.nasa.gov/search.jsp?R=20160009154 2019-08-29T23:41:34+00:00Z
Images courtesy of Wikimedia Commons Images courtesy of Creative Commons
MASS
RISK
$$$$
FEASIBLE
Images courtesy of Creative 
Commons
First Stage
Third Stage
Command 
Module
Fourth Stage
Second Stage
Diameter: 33 ft Car
What Was 
Returned
• 6.6M lbs sat on the 
launch pad.  
• But only 12.8K lbs came 
back. 
• This is equivalent to 
taking a road trip in a car
and coming back with 
just the left front wheel’s   
lug nuts!
SATURN V
Image courtesy of NASA
Square peg in Round Hole? No problem! 
Image courtesy of NASA & Made in Space, 
Inc. 
• ISM is responsible for developing the on-demand manufacturing capabilities that will 
be required for affordable, sustainable operations during Exploration Missions (in-
transit and on-surface) to destinations such as Mars. This includes advancing the 
needed technologies, as well as establishing the skills & processes (such as 
certification and characterization) that will enable the technologies to go from novel 
to institutionalized. 
• These technologies are evolving rapidly due to terrestrial markets. ISM is leveraging 
this commercial development to develop these capabilities within a realistic 
timeframe and budget. 
• ISM utilizes the International Space Station (ISS) as a test-bed to adapt these 
technologies for microgravity operations and evolve the current operations mindset 
from earth-reliant to earth-independent. 
On-demand Manufacturing Capability for 
Exploration Missions
Design   
Optimize  
Characterize Certify
TECHNOLOGIES SKILLS & PROCESSES
More than just 3D Printing….
In-space Manufacturing Technology Development Areas
MULTI 
MATERIAL 
3D PRINTING
PRINTED 
ELECTRONICS
RECYCLER
EXTERNAL 
STRUCTURES 
& REPAIRS
ADDITIVE 
CONSTRUCTION
PRINTABLE 
SATELLITES
ISM Technologies Under Development for Sustainable 
Exploration Missions
Contour Crafting 
Simulation Plan
for Lunar Settlement 
Infrastructure Build-Up
B. Khoshnevis, USC
Recycling/Reclaiming 
3D Printed Parts 
and/or packing 
materials into 
feedstock materials. 
This capability is 
crucial to 
sustainability in-
space. 
Leverage ground-
based developments to 
enable in-space 
manufacturing of 
functional electronic 
components, sensors, 
and circuits.
Image: Courtesy of Dr. 
Jessica Koehne 
(NASA/ARC) Illustration of a lunar 
habitat, constructed 
using the Moon's soil 
and a 3D printer. 
Credit: Foster+Partners 
Astronauts will perform 
repairs on tools, 
components, and 
structures in space 
using structured light 
scanning to create 
digital model of damage 
and AM technologies 
such as 3D Print and 
metallic manufacturing 
technologies (e.g.        
E-beam welding, 
ultrasonic welding, 
EBF3) to perform the 
repair. Image: NASA
Additively 
manufacturing metallic 
parts in space is a 
desirable capability for 
large structures, high 
strength requirement 
components (greater 
than nonmetallics or 
composites can offer), 
and repairs. NASA is 
evaluating various 
technologies for such 
applications. Image: 
Manufacturing 
Establishment website
The combination of 
3D Print coupled with 
Printable Electronics 
enables on-orbit 
capability to produce 
“on demand” 
satellites. 
In-space Manufacturing (ISM) Path to Exploration
EARTH RELIANT PROVING GROUND EARTH INDEPENDENT
Commercial  
Cargo and Crew
Space Launch 
System
ISS
Asteroids
Earth-Based Platform
• Define Capacity and Capability Requirements (work with EMC Systems on 
ECLSS, Structures, Logistics & Maintenance, etc.)
• Certification & Inspection Process
• Material Characterization Database (in-situ & ex-situ)
• Additive Manufacturing Systems Automation Development
• Ground-based Technology Maturation & Demonstrations (i.e. ACME Project)
• Develop, Test, and Utilize Simulants & Binders for use as AM Feedstock
ISS Platform
• In-space Manufacturing Rack 
Demonstrating:
o 3D Print Tech Demo (plastic)
• Additive Manufacturing 
Facility 
• Recycling 
• On-demand Utilization 
Catalogue 
• Printable Electronics 
• In-space Metals 
• Syn Bio & ISRU
• External In-space Mfctr. & Repair 
Demo
Planetary Surfaces  Platform
• Additive Construction, Repair & 
Recycle/Reclamation Technologies (both In-
situ and Ex-situ )
• Provisioning of Regolith Simulant Materials 
for Feedstock Utilization 
• Execution and Handling of Materials for 
Fabrication and/or Repair Purposes
• Synthetic Biology Collaboration
* Green text indicates ISM/ISRU collaboration
In-space Manufacturing Phased Technology 
Development Roadmap
• In-space:3D 
Print: First 
Plastic Printer 
on ISS Tech 
Demo 
• NIAC Contour 
Crafting
• NIAC Printable 
Spacecraft
• Small Sat in a 
Day
• AF/NASA Space-
based Additive 
NRC Study
• ISRU Phase II 
SBIRs
• Ionic Liquids
• Printable 
Electronics
• 3D Print Demo
• Future Engineer 
Challenge 
• Utilization 
Catalogue
• ISM Cert 
Process
• Add. Mfctr. 
Facility (AMF)
• In-space 
Recycler SBIR
• In-space 
Material 
Database
• External In-
space 3D 
Printing
• Autonomous 
Processes
• ACME Simulant 
Dev. & Test for 
Feedstock; 
Ground Demo
ISS: “Fab Lab” 
Utilization/Facility 
Focus
• In-space Recycler 
Demo
• Integrated Facility 
Systems for 
stronger types of 
extrusion materials 
for multiple uses 
including metals & 
various plastics
• Printable 
Electronics Tech 
Demo 
• Synthetic Biology 
Demo
• Metal Demo 
Options
• ACME Ground 
Demos 
Lunar, Lagrange 
FabLabs
• Initial 
Robotic/Remote 
Missions
• Provision 
feedstock
• Evolve to utilizing 
in situ materials 
(natural 
resources, 
synthetic biology)
• Product: Ability to 
produce, repair, 
and recycle parts 
& structures on 
demand; i.e.. 
“living off the 
land”
• Autonomous final 
milling to 
specification
Mars Multi-Material 
Fab Lab
• Provision & Utilize 
in situ resources 
for feedstock 
• FabLab: Provides 
on-demand 
manufacturing of 
structures, 
electronics, & parts 
utilizing in-situ and 
ex-situ (renewable) 
resources. Includes 
ability to inspect,  
recycle/reclaim, and 
post-process as 
needed 
autonomously to 
ultimately  provide 
self-sustainment  at 
remote destinations.
3D Print Tech Demo
Planetary 
Surfaces 
Points Fab
• Transport 
vehicle and 
sites would 
need Fab 
capability
• Additive 
Construction 
& Repair of 
large 
structures
Ground & Parabolic 
centric:
• Multiple FDM Zero-
G parabolic flights 
• Trade/System 
Studies for Metals
• Ground-based 
Printable 
Electronics/Spacec
raft
• Verification & 
Certification 
Processes under 
development
• Materials Database
• Cubesat Design & 
Development
Lagrange
Point
Lunar
Mars
Asteroids
2014 2015 - 2017 2018 - 2024 2025-35 2035+
Plastic Printing 
Demo
Recycler
AMF
Metal Printing
Fab Lab
Digital 
Mfctr.
Self-repair/
replicate
Pre-2012
ISS Serves as a Key Exploration Test-bed for the Required Technology Maturation & Demonstrations
Earth-based Demos: Ground & ISS Exploration
External In-
space Mfctr
* Green text indicates ISM/ISRU collaboration
Utilization 
Testing
Mat. 
Char.
Clamps
Images courtesy of NASA
• The 3D Print Tech Demo launched on SpaceX-4 
(9/21/14) and was installed in the Microgravity Science 
Glovebox on ISS. The printer was designed and built by 
Made in Space, Inc. under NASA Small Business 
Innovation Research contract. 
• To date, 21 parts have been printed in space (13 unique 
designs); the printer functioned nominally.  
• First part “emailed” to Space: 3D Print of a ratchet tool 
demonstrated on-demand capability by uplinking a part 
file that was not pre-loaded to the 3D Printer. 
• The first flight samples were ‘unboxed’ at NASA MSFC 
in April 2015 and underwent test & analyses to compare 
to ground control samples. Results to be published in 
Spring 2016. 
3D Printer International Space Station (ISS) 
Technology Demonstration Initial Samples
Printer Performance Capability
Mechanical Property
Test Articles Functional Tools
Calibration Hole Resolution Feature Resolution Layer QualityOverhang
Cubesat 
Clip
Container
Crowfoot Wrench
Compression
Flex Torque
Tensile
The Capability to Manufacture Items in Space is a Critical 
Enabler for the Path to Mars
“As crews head to Mars, there may be items that are unanticipated or that break during the 
mission. Having the ability to manufacture new objects on demand while in space will greatly 
benefit missions. The 3-D Printing in Zero-G Technology Demonstration validates that a 3-D 
printer works normally in space. This is the first step towards establishing an on-demand machine 
shop in space, which is a critical enabling component for crewed missions to deep space.”
1.
Understanding 
how to 
manufacture 
items in space 
(3-D Printing)
NASA Article Published on 9/15/15 Ranks “Understanding how to manufacture items in 
space” as the #1 was that ISS is helping us on our journey to Mars!!!  
NASA In-Space Manufacturing (ISM) Activities
3D Printer Installed in MSG on ISS
Ratchet, Internal Mechanism (flight)
Compression Coupon (flight)
3D Printer International Space Station Technology 
Demonstration
• The first flight samples were received at MSFC on 3/17/15.
• All specimens have undergone photographic inspection, 
structured light scanning, CT, and 2D X-ray evaluation. 
Mechanical test coupons from the flight experiment have 
completed destructive testing.  All testing has been completed.
• Data Analyses TIM to review and “vet” results, hypotheses, and 
next-steps.
• Full results for these initial parts to be published externally in 
February 2016. 
• Next operations for 3D Print Tech Demo to resume in late 
2015/early 2016 and will include additional statistical samples, 
ISS Oxygen Generator System (OGS) Airflow Adaptor, & STEM 
part(s).
AMF - Additive Manufacturing Facility - Made In Space
• ISS Commercial printer owned by Made in Space, Inc. with 
anticipated launch on Space X 8 (early CY 2016)
• Incorporates lessons learned from 3D Printer ISS Tech Demo
• NASA has SBIR Ph. II Enhancement for initial AMF prints and 
developing IDIQ for additional on-orbit ops. 
• Expanded materials capabilities: ABS, ULTEM, PEEK
Additive 
Manufacturi
ng Facility
NASA In-Space Manufacturing Activities (cont.)
Material Characterization Database Development
• Objective: Characterize microgravity effects on printed parts and 
resulting mechanical properties; Develop design-level database for 
microgravity applications for incorporation into the MSFC Materials 
and Processes Technical Information System (MAPTIS)
On-demand ISM Utilization Catalogue Development
• Objective: Develop a catalogue of pre-approved parts for in-space 
manufacturing and utilization. This includes establishing the safety 
and certification processes to institutionalize this capability. 
• ISM Design & AM experts have been working with ISS users, and 
NASA Exploration System Designers. 
External In-space Manufacturing (EISM)
• Objective: External Additive Manufacturing shows great promise 
for Exploration missions. Targeted Areas of Interest include
autonomous, on-demand manufacturing technologies which work 
in external space environments
• NASA and Defense Advanced Research Projects Agency 
(DARPA) are planning the release of an EISM Broad Agency 
Announcement (BAA) in early 2016 to explore the technologies 
available today that could be utilized for a future in-space 
demonstration. 
Compression Testing of 
Mechanical Flight Sample 
7/21/15
ISM 
Printed 
OGS AAA 
Flow 
Adaptor 
for 
Ground 
Testing
In-space Recycler ISS Tech Demonstration Development
• Objective: Recycle 3D printed parts into feedstock to help close logistics loop.
• Phase I recycler developments completed by Made In Space and Tethers 
Unlimited.
• Phase II SBIR (2014) awarded to Tethers Unlimited for the In-space Recycler 
for proposed ISS Technology Demonstration in FY2017. 
Common-use Packaging & 3D Printing Materials
• Objective: Identify common-use materials for packaging i.e. foam, bubble wrap, 
plastic bags, etc.) and 3D printing feedstock. 
• Three companies selected for Ph. 1 award in 2015 including TechShot, 
Cornerstone Research, & Tethers Unlimited, Inc.  
Multi-material “Fab Lab” with Printable Electronic Capability
• Objective: Develop capability for on-demand, in-space manufacturing for 
multiple materials, electronics, inspection, automated part removal, etc. 
• Currently working to “print” RFID Antennae and Tags for NASA Logistics 
Reduction Team. 
• Utilizing patented dielectric and conductive inks developed at NASA 
Additive Construction by Mobile Emplacement (ACME)
• Objective: Develop a capability to print custom-designed expeditionary 
structures on-demand, in the field, using locally available materials (lunar and 
martian regolith for NASA, concrete for terrestrial applications). 
• Joint initiative between NASA STMD and the U. S. Army Corps. of Engineers.
• Technology Development and Curved Wall demonstration in FY15 and FY16 
with full-scale demonstration in FY17. 
NASA In-Space Manufacturing Activities (cont.)
Tethers 
Unlimited 
SBIR to 
Develop 
ISS 
Recycler 
Tech Demo
Additive construction Concept on 
extraterrestrial surface
Common Use Materials for 3D 
Printing & Packaging 
Printable Electronics
16
In-space Manufacturing STEM & Outreach: Leveraging External 
Platforms for Technology and Skillset Development 
Future 
Engineers 
Crew Tool 
Winner: Multi-
purpose 
Maintenance 
Tool (MPMT)
Future Engineers STEM Program: National K-12 challenges focused 
on designing 3D printed parts; made possible thru a Space Act 
Agreement (SAA) between NASA and American Society of Mechanical 
Engineers (ASME). 
• Website includes tutorials on how to design parts for 3D printing, 
links to free design tools aimed at various ages,  videos on living & 
working in space, and design galleries with all previous student 
entries. (www.futureengineers.org)
• Motto is, “Engineering is a state of mind, not a degree” with the  goal 
to instill confidence in students by equipping them with the skills to 
make whatever they can imagine. 
• Challenges have two age divisions: Junior (K-12) and Teen (13-18)
• To date, two national K-12 Challenges have been conducted.
o 1st Challenge was to design a tool that astronauts could use on 
ISS. Teen winner’s part will be printed on ISS later this year. 
o 2nd Challenge was to design any sort of space container 
(science samples, food, etc.) was announced on 5/12/15 and 
closes 8/2/15. 
o The next two challenges are under development with the first 
expected to be announced in February 2016.
NASA’s Center for Excellence for Collaborative Innovation:
• GrabCAD Handrail Clamp Assembly Challenge: Developed 
challenge to design a 3D Printed version of the Handrail Clamp 
Assembly commonly used on ISS using materials and dimensions of 
on-orbit 3D Printer. 
• Received nearly 500 entries in three weeks with five winners were 
selected; NASA maintained all IP rights. Challenge was conducted 
for under $3K on NASA credit card purchase order.
ISS 
Handrail 
Clamp 
Assembly 
GrabCAD
(top) 
& 
traditional 
(bottom)
Future Engineer Winners
In-space Manufacturing Initiative  Summary
17
• In-space Manufacturing offers:
• Dramatic paradigm shift in the development and creation of space architectures
• Efficiency gain and risk reduction for low Earth orbit and deep space exploration
• “Pioneering” approach to maintenance, repair, and logistics will lead to sustainable, 
affordable supply chain model.
• In order to develop application-based capabilities in time to support NASA 
budget and schedule, ISM must be able to leverage the significant commercial 
developments. 
• Requires innovative, agile collaborative mechanisms (contracts, challenges, SBIR’s, etc.)
• NASA-unique Investments to focus primarily on adapting the technologies & processes to 
the microgravity environment.
• We must do the foundational work – it is the critical path for taking these 
technologies from lab curiosities to institutionalized capabilities. 
• Characterize, Certify, Institutionalize, Design for AM
• Ultimately, ISM will utilize an ISS US Lab rack to develop an integrated “Fab 
Lab” with the capability to manufacture multi-material parts with embedded 
electronics, inspect the parts for quality, and recycle multiple materials into 
useable feedstock that will serve Exploration Missions. 
In order to provide meaningful impacts to Exploration Technology needs, the ISM 
Initiative Must Influence Exploration Systems Design Now.


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