Factories in space

Instead of hauling tools and replacement parts from Earth, we could be creating them in a multi-material fabrication laboratory, or Fablab, in space. After positive response, NASA has extended its NEXTSTEP subprogramme focused on developing deep space habitation concepts, engineering design and development, and risk reduction efforts leading to a habitation capability in cislunar space. Now the organisation is seeking proposals for development of a first-generation, in-space Fablab, for space missions. The Fablab development strategy will be implemented in three phases, culminating in successful demonstration of a commercially developed Fablab on the International Space Station. In Phase 1, ground prototypes have to capable of remote-controlled operations from Earth to manufacture multi-material components, including metals.

Fablab is a logical extension of in-space manufacturing following the success of 3D printing plastics on the Space Station, according to Jason Crusan, director of NASA’S advanced Exploration Systems division, which also manages NEXTSTEP.

“We’ve already seen the benefits of on-demand manufacturing for tools and replacement parts on station,” said Crusan. “We want to increase the number of materials we can use to manufacture items on-demand in space and improve overall manufacturing efficiencies as well.” It’s foreseen that in-space manufacturing should become an end-to-end process, capable of recycling feedstock as well as harvesting it from extraterrestrial sources. The idea will be an integral part of sustainable exploration missions, said Jim Reuter, deputy associate administrator for the organisation’s Space technology programme. “This is a rapidly evolving, disruptive area in which NASA wants to continue working with industry and academia to develop these technologies through collaborative mechanisms such as this one.”

International Space Station astronaut Barry “Butch” Wilmore holds a science sample container that took two hours to make in December 2014. The container was the first object to be printed with two parts: a lid and a container.

Multi-material sensors like the one pictured right are vital to space ship operations, and need to be fabricated on demand during deep space missions.