A gravity-independent powder-based additive manufacturing process tailored for space applications

The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions independently of the gravitational environment and with no restriction on feedstock powder flowability. Based on a specific sequence of boundary loads applied to the granular packing, powder is transported to the printing zone, homogenized and put under compression to increase the density of the final part. The powder deposition process is validated by simulations that show the homogeneity and density of deposition to be insensitive to gravity and cohesion forces within a discrete element method (DEM) model. We further provide an experimental proof of concept of the process by successfully 3D printing parts on-ground and on parabolic flight in weightlessness. Powders exhibiting high and low flowability are used as model feedstock material to demonstrate the versatility of the process, opening the way for additive manufacturing of recycled material.