In-Space Manufacturing Portfolio (ISM)

The In-Space Manufacturing (ISM) portfolio provides a solution towards sustainable, flexible missions through on-demand fabrication, replacement, and recycling capabilities to support critical systems, habitats, and mission logistics and maintenance. These capabilities can provide tangible cost savings by reducing launch mass and volume; reducing risk by decreasing dependence on spares; reducing over-designing systems for reliability instead of maintainability; enabling the fabrication of large structures; and enabling crew to respond to unanticipated scenarios. ISM is developing these capabilities by leveraging new technologies being developed terrestrially and adapting them for operations in environments with varied pressure, gravity, temperature, and radiation.

The International Space Station (ISS) serves as a one-of-a-kind microgravity test bed on the ISM technology development roadmap. The current ISS logistics model is heavily dependent upon Orbital Replacement Units (ORUs) for system-based (vs. component level) repair and maintenance. ISM provides an approach which will help to enable sustainable, affordable mission operations and logistics. Additionally, ISM is key to addressing significant logistics challenges for long-duration missions by reducing launch and spares mass, providing flexible risk coverage, and enabling new capabilities that are required for sustainable Exploration missions.

Potential ISM applications include free-flying and EVA missions. Large-scale structure fabrication will need to be performed outside a controlled environment in LEO or on the Moon or Mars and the ISM project is well-positioned to enable those activities.

The current ISM portfolio includes two projects: On-Demand Multi-material Manufacturing (ODMM), currently funded by both ESDMD/MCO and STMD/GCD; and On-Demand Manufacturing of Electronics (ODME), funded by STMD. Recycling/reuse and outfitting are additional areas of interest but are not currently funded.

The ODMM project is pursuing the development of a multi-material Fabrication Laboratory, or FabLab, from Techshot, Inc., a subsidiary of Redwire, Inc. FabLab uses bound metal additive manufacturing to extrude a polymer/metal feedstock blend to produce a "green" (low-density) part. The green part is then transferred into a furnace, where the polymer constituents are removed, and the remaining metal is consolidated. FabLab has the potential to expand the material processing capability to multiple metals as well as polymers and electronics, with the vision of providing an adaptable capability for future missions. This adaptable capability enables long duration missions through substantial risk reduction based on the ability to fabricate parts for unforeseeable needs.

ODME is developing on-demand manufacturing of a wide range of electronics, sensors, and power & energy devices for manufacturing in microgravity on the ISS and on the lunar surface to support Artemis surface construction and exploration activities. The project is developing the next generation of deposition systems for printing precise patterns of electronics in microgravity and extreme environments. ODME is also developing materials and sensors to support self-powered sensor networks and replacement electronics for Logistics Reduction.

It should be noted that FabLab is a key component of ODME – the advanced toolplate in the print module is capable of the very fine printing of circuit boards and other electronic components. ISM is currently seeking opportunities to send up FabLab without the furnace module initially (to demo ODME processes) and then later send up the furnace module for ODMM development.

ODME is also leading the NASA Commercialization initiative for manufacturing semiconductors in Low Earth Orbit (LEO). ODME is developing next-generation materials, processes, and device designs to take maximum advantage of microgravity for semiconductor manufacturing to offer significant competitive advantages over terrestrial semiconductor manufacturing. The enabling of these new semiconductor technologies by ODME will also advance NASA's capability to manufacture next-generation electronics in space for exploration missions and lunar applications.

The capability to produce hardware on-demand, using additive manufacturing (3D printing) technologies, will directly lower cost and decrease risk by having the exact part or tool needed in the time it takes to print. This project is the first step towards realizing a manufacturing facility in space that is a critical enabling component of any deep space exploration mission.

Furthermore, the availability of on-demand manufacturing of electronic devices is a critical element for NASA's future in-space and planetary expeditions. Electronic devices such as sensors, communication electronics/infrastructure (cabling), printed energy storage devices, and power generation elements will all need to be manufactured on-demand in an orbital or extraterrestrial habitat environment to replace failed components or manufacture new systems on long duration, earth independent missions.

Customers for ISM include NASA deep space missions, specifically the Mars Campaign Office, the Space Technology Mission Directorate's Game Changing Development Program, and the ISS Program. Potential US Government partners include the Departments of Defense, Energy, and Commerce.

Some of the savings associated with having versatile welding/cutting/additive manufacturing capabilities available during a mission include:

1. Reduction of up-mass and volume for spare parts, which results in fewer launches (i.e., decreased cost and schedule to achieve exploration missions).
2. Elimination of flight time from Earth for delivery.
3. Reduction of production time.
4. The ability to print parts and/or architectures never conceived due to the unique attributes of additive manufacturing.
5. Elimination of launch load constraints on part designs.
6. Risk reduction for long duration missions where potential component failure cannot be anticipated.
7. The potential ability to manufacture structures outside of the constraints of a payload fairing.

In addition, potential new work in outfitting and autonomous setup prior to arrival will benefit long duration missions. The ability to enable the fabrication of most all infrastructure will be key to a sustainable human presence on other worlds.

The terrestrial commercial market for these technologies is disruptive and evolving quickly. The NASA ISM project utilizes mechanisms such as Broad Agency Announcements (BAA), Cooperative Agreement Notice (CAN), and Small Business Innovation Research (SBIR) awards to work closely with industry to leverage these rapid technology advances. This results in stimulating the terrestrial economy in this area, while utilizing limited NASA resources to focus on adapting these technologies for application in the environments present in space.

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.

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.