Low Cost Polymer Extrusion Real Time Defect Detection and In Situ Process Control

Fused-filament fabrication (FFF) has received considerable investment from the aerospace industry because it offers the enticing capability of on-demand fabrication of complex spare parts, while simultaneously expanding the engineering design space and minimizing costs for low-volume part production. This is particularly important to the aerospace industry where storage space for parts is limited, part count is low, and often times getting parts on location (i.e. space, the moon, Mars) is very expensive. NASA has been a major leader in implementing additive manufacturing (AM) in current systems, but adoption is still slow because of post-process inspection requirements. If parts are to be made on-site in non-terrestrial environments post-process inspection may not be available, so closed-loop control of FFF is necessary. Consequently, a significant opportunity exists to develop tools that bridge the quality control gap between current FFF technology and fully-closed-loop systems.

3D Printed Hybrid Rocket Grains 3 current customers pursuing this application Companies are forecasting dozens of machines to meet rate demands 3D printing fuel on Gateway, Lunar and Martian facilities > Future “gas stations” Shelters & Laboratories Benefit from the tools, furniture, HVAC, and appliances 3D printed from the lightweight pellet feedstock Light weight feedstock can be supplied in bulk to support unlimited applications Future waste streams can be converted into feedstock

A wide range of markets have turned to pellet extrusion technology for serial production solutions (HVAC, commercial goods, agriculture, foundry, aerospace, and automotive). Each of these markets are leveraging the technology for tooling, prototyping, and low rate high mix product demands.

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.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.