Science

Lockheed, PADT, Stratasys Collaborate on 3D Printing for NASA Spacecraft Parts

April 18, 2018 18:24·
This 3-D printed Orion docking hatch cover. Lockheed Martin

This 3-D printed Orion docking hatch cover. Lockheed Martin

NASA's Orion spacecraft is destined for great things.

Orion's next test flight, Exploration Mission-1 (EM-1), will be the first integration mission with the world's most powerful rocket, the Space Launch System, where Orion will fly thousands of miles beyond the moon during an approximately three-week mission.

The concept of 3D printing, while it has applications in nearly every sector, is being actively pursued in connection with space exploration, especially amidst the race to Mars, since 3D printed parts be printed remotely without the need of extensive manufacturing set-ups.

Executives at Stratasys are hopeful that its new 3D printing plastic, initially adopted by the space industry, will also find use in civil aviation, electronics, and packaging.

The parts are being developed jointly by USA defence contractor Lockheed Martin, Stratasys, and engineering firm PADT using new materials that can withstand the extreme temperatures and chemical exposures of deep space missions.

"In space, for example, the material will accumulate a charge. Part stability and repeatability are important and need to pass NASA's requiring screening and recognition procedure", Scott Sevcik, vice president of making at Stratasys, stated in the release.

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The materials that go into the Orion's make-up have to meet specific requirements of both quality and performance, Sevcik explained.

This 3-D printed Orion docking hatch cover is made of Polyetherketoneketone (PEKK), an advanced thermoplastic with electro-static dissipative capabilities.

NASA prepares to utilize more than 100 3D printed production parts on board- all which will be crafted in cooperation with Lockheed Martin, Stratasys, and PADT.

"Working with PADT, Stratasys, and NASA has enabled us to achieve highly consistent builds that move beyond the realm of prototyping and into production", he said.

"Those 100 parts might replace 500 or 600 parts, as the printed technology can be used to create complex geometrical shapes", said Reeves.

For instance, the previously complex draft of Orion's docking hatch cover has been reduced to a simpler design, made up of only six components - all individually 3D-printed.

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