3D printer shot into space for 140 seconds, prints toy shuttle at super speed

Guess what hitched a ride on Virgin Galactic’s latest mission? A high-tech 3D printer specially designed for space applications.

For astronauts on distant missions, 3D printing could come to their rescue when spare parts are running low. The technique can simply fabricate and repair any vital spacecraft parts that break far from Earth.

UC Berkeley engineers have developed this advanced 3D printer called SpaceCAL to save the day for astronauts on missions to the Moon and Mars. This microgravity 3D printer took its first suborbital space flight aboard the VSS Unity space plane on Virgin Galactic’s mission 07 in June.

It spent a quick 140 seconds floating around and even autonomously printed some cool stuff, like the space shuttle figurine, using a special liquid plastic.

“SpaceCAL performed well under microgravity conditions in past tests aboard parabolic flights, but it still had something to prove,” said Ph.D. student Taylor Waddell.

He added: “We hope that someday it may be used to manufacture everything from parts and tools for spacecraft to new contact lenses and dental crowns for crew members.”

NASA provided $1.4 million in grant funding and engineering support for this project.

Employs new printing technique

SpaceCal uses a new type of additive manufacturing technique called Computed Axial Lithography (CAL). Berkeley team developed this 3D printing technology in 2017 and has been actively working to validate its readiness for space travel.

This 3D printer is said to be super fast and efficient, creating parts in 20 seconds. The developers highlight that this extraordinary speed sets it apart from other 3D printing technologies.

This 3D printing method uses light to quickly print complex, solid shapes from a viscous liquid. This light-based technique holds the potential to broaden the types of 3D shapes printable in space.

CAL’s ability to print parts on demand could be a game-changer for long space missions. It eliminates the need for astronauts to lug around thousands of spare parts, significantly reducing overall weight.

“You can reduce that upmass, make these missions go faster, and reduce risk by bringing manufacturing technologies with you,” said Waddell in the press release.

Moreover, the autonomous style could allow the astronauts to be less worried about the 3D printing process.

SpaceCal has 3D printed 60 materials on Earth

On Earth, the 3D printer has been able to fabricate over 60 different materials, including silicones, glass composites, and biomaterials.

“So, with the cabin, if your spacecraft is breaking down, you can print O-rings or mechanical mounts or even tools,” Waddell said. “But CAL is also capable of repairing the crew. We can print dental replacements, skin grafts or lenses, or things personalized in emergency medicine for astronauts, which is very important in these missions, too.”

Interestingly, Waddell and his team have found that this printer can produce certain parts in microgravity with high efficiency as compared to Earth.

Building on their success, Waddell and his colleagues are teaming up with NASA to develop 3D-printed medical objects for space travel. This could be anything from a dental crown to a wound closure device, a significant step forward for astronaut well-being on long missions.”

The future holds even more promise. The team envisions CAL printing complex human organs. Thanks to a NASA grant, this exciting possibility will be tested on the International Space Station soon.