Automated In-Process Quality Control of Recycled Filament Production and FDM Printers

Cornerstone Research Group Inc.’s (CRG) demonstrated expertise in polymer AM materials development, systems engineering, and feedstock recycling for ISRU offers NASA the opportunity to obtain AM process monitoring and control systems for online quality control of feedstock production and printed parts. CRG’s proposed approach applies sensors, hardware, and software algorithms to monitor and adjust feedstock production AND printing processes in real time as well as certify feedstock and print quality. Hardware and software developed on this program by CRG will be integrated into future platforms initially targeting the ERASMUS Recycler sub-module already under development to support NASA’s ISM. Integration of CRG’s in-situ automated quality control technology into a duplicate of the ERASMUS Recycler submodule will occur during this Phase II effort.

Improvements to the ERASMUS multi-material recycle/ printer system as well as future systems such as FabLab In-situ print and filament quality monitoring Volumetric consolidation of ISS waste plastics Recycling ISS waste plastics into 3D printable filament Reduce payload needs for AM fabrication in-space 3D printers with improved layer-to-layer adhesion

Novel 3D printing feedstock materials Improved consumer-level FDM feedstock production In-situ filament fabrication monitoring and corrective feedback add-on In-situ print quality monitoring 3D printers with improved layer-to-layer adhesion

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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