Evaluation of Computed Axial Lithography for rapid, volumetric additive manufacturing under low-gravity conditions

The evaluation of Computed Axial Lithography (CAL) for rapid, Volumetric Additive Manufacturing (VAM) under low-gravity conditions experiment will test a new additive manufacturing technique that enables contactless printing of biomaterials and engineering resin using the principles of computed tomography. The objective for a parabolic flight test is to successfully print both biomaterial and engineering components in the same machine during microgravity conditions. The data from this flight test – including fluid flow velocity refractive index and printing accuracy – will demonstrate the technique’s scalability.

Problem Statement 
Additive manufacturing in space allows astronauts to efficiently build or repair needed items during a mission without having had to bring those items with them from Earth. Some additive manufacturing techniques can even be used to fabricate parts of human organs, which could be critical for a crew member with organ damage on a long-duration mission.This technology could improve current space-based bioprinting techniques, which have the potential to alter cell growth or are not readily adaptable with a wide variety of materials. 

Technology Maturation 
Parabolic flight tests will explore the effects of reduced gravity on the technology’s sedimentation, resin flows, print fidelity, and degree of conversion, with a particular focus on low-viscosity resins that are more challenging to print under normal gravity conditions.Overall, testing in microgravity aims to mature CAL to TRL 6. Doing so will advance its scalability, modularity, and versatility in printing both biomaterial and engineering components in the same machine.

Summary of Flight Test
2022-05-09 Our UC-Berkeley group successfully managed to manufacture over 120 3D printed parts in a microgravity environment. Some parts took as little as 10 seconds to create, with a max time of 24 seconds. Not only did this process work in a microgravity environment, but early evidence shows that it functioned better than in a traditional gravity effected environment. This technology could be used to print O-rings for sealing, cell tissue for medical treatment, repair broken items by conjoining them, on top of manufacturing many traditional mechanical tools and parts.
2022-11-15 This experiment showed in greater depth the possibilities of what Computed Axial Lithography (CAL) in microgravity can do, from printing higher quality parts, to becoming a popular research platform for the field.
Additionally a new test was conducted that demonstrated the post processing of parts in a microgravity environment.
2024-06-08 SpaceCAL has successfully printed and post-processed multiple parts in space! It fully validates the technology for a spaceflight hardware environment.

This user-friendly, highly efficient additive manufacturing technique demonstrates the potential to significantly advance in-space 3D printing capabilities as well as in situ resource utilization.Computed axial lithography could provide critical life support for astronauts through bioprinting organ and could also fabricate vital mechanical components to perform spacecraft repairs. This would benefit NASA missions, the commercial space industry, and the nation.

Future Customers
- Producing flexible components like gaskets and seals
- Tissue modeling research
- Bioprinting human organs
- Printing dental components

This is early/mid-stage (TRL 4) — 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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