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Completed TRL 4 (started at 2, targeting 4)
WARP-3D will demonstrate feasibility of a novel resistance wire directed energy deposition (RW-DED) technology by delivering a prototype that can precisely deposit metallic wire feedstock onto a substrate in a programmed pattern using Joule heating for localized joining. This new technology requires less energy than Wire-Arc AM processes and is amenable to dissimilar metals joining which enables the production of functionally graded components. Prototype development aims to achieve a multi-layer component build with >99% relative density.
A low heat-input metal additive manufacturing (AM) process with reduced energy consumption is desired for on-orbit printing of metallic components. Such a capability is critical to the success of future in-space assembly and manufacturing (ISAM) endeavors that demand versatility and low power draw. RW-DED technology addresses STMD challenges in Power and Energy Storage and ISRU by enabling power-efficient production of components manufactured from extra-terrestrial in-situ materials in microgravity/extreme environments and facilitates breakthrough material research in multi-functional and multi-material systems.
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