On-Orbit Additive Manufacturing Using Recycled Waste

re:3D Inc. proposes to build a functional benchtop demonstration unit of an integrated waste-to-print recycling system based on a granulation mechanism and 3D printer capacble of turning thermoplastic waste generated from logistics foam available from in-space applications into functional and useful objects through the use of material extrusion additive manufacturing (AM). This will be a low size, weight and power (SWaP) engineering prototype based on re:3D's commercial Gigabot X (GBX) technology and new innovative methods to shred the bulk foam and transport the resulting loose granulate in a contained system. The design will address the unique challenges of operating in microgravity with limited space and power resources.

NASA has specifically identified packaging material as an upmass of significant logistical overhead. This material is placed in orbit at appreciable cost, and its reuse through recycling must be considered - particularly for lunar and deep space missions which have limited opportunities for resupply and waste disposal. Off-planet human habitation will require point-of-use recycling/upcycling solutions which can be provided by additive manufacturing technologies. A waste-to-print system integrated in a small form factor would be of use to US Navy submarines on active deployment which can be away from supply and repair opportunities for months at a time. Such a system could also be of interest to individuals and families looking for a personal recycling solution, reducing the carbon footprint of recycled goods by removing the need for transporting waste materials between multiple processing plants.

This is early/mid-stage (TRL 2) — 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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