The Newfrontier

3D printers and the intrigue of space manufacturing.

- Matthew Flynn

In 2014, astronaut Barry “Butch” Wilmore grabbed headlines when a picture of him holding a ratchet on the International Space Station (ISS) made its way back to Earth. Why was this so newsworthy? The ratchet itself was manufactured in space using a 3D printer with the design instructions sent up to the station from the ground.

This seemingly simple example of 3D printing in space could have major repercussions in manufacturing and space exploration as the technology is advanced; Wilmore’s ratchet likely is just the beginning. 3D printers with increasing power and more wide-ranging uses could make space manufacturing the way of the future— capable of maintaining spaceships on distant travels, creating new technology for use at home, and even growing human organs.

MADE IN SPACE

The printer used to make the ratchet was the Additive Manufacturing Facility (AMF), developed by the NASA research facility Made in Space. The AMF was specifically designed to be able to handle the harsh conditions of being launched into space and survive in orbit for the lifespan of the ISS. The two AMFs on the space station have since printed more than 200 items onboard the ISS, ranging from tools to spare parts used for upgrades.

Of course, Made in Space is interested in more than just assisting with repairs on the International Space Station. The California-based research facility has bigger goals which will be achieved through their technology known as Extended Structure Additive Manufacturing (ESAM).

In 2017, ESAM passed the vacuum test required by NASA and, in early 2018, helped Made in Space set the Guinness World Record for the longest non-assembled 3D printed piece. The piece, a polymer beam, was 123.7 feet long—almost the size of one of the solar arrays which are used to power the ISS. Made in Space claims the only reason their polymer beam wasn’t longer is because they ran out of room.