Next Generation Additive Manufacturing for Space Applications

This collaborative research effort focuses on the development of a methodology for quality control and optimization of processing parameters for Additive Manufacturing (AM) technological processes. The main application of the expected outcomes is developing a design-in-manufacturing methodology to produce structural parts in the conditions when processing parameters have to be adjusted during printing. This application is of particular interest to NASA Space Technology Mission Directorate (STMD) for developing materials repurposing technology crucial for 3D-printing in space [2].

The project is strongly supported by NASA’s Johnson Space Center, The Ames Research Center and White Sands Test Facility. The research is aligned with the following Technology areas indicated in the NASA 2020 Technology Taxonomy: 12.1.1 (Lightweight Structural Materials), 12.2.2 (Design and Certification Methods), 12.4.1 (Manufacturing Processes), 12.4.2 (Intelligent Integrated manufacturing), and 12.4.5 (Nondestructive Evaluation and Sensors).

The ultimate goal of our project is to propose a novel methodology that integrates measurement techniques (e.g. in-situ sensing modalities) and material characterization (e.g. ex-situ material evaluation) with the optimization of AM processing parameters. Our research will focus on printing specimens from titanium and aluminum alloys and functionally graded materials using the Directed Energy Deposition (DED) method. Initial input parameters will be used for manufacturing the first set of specimens; the manufacturing process will be monitored using in-situ sensors (infrared, optical, and acoustic sensors). The printed specimens will be tested using ex-situ testing (X-ray computed tomography, electrical impedance, and ultrasound testing) and microscopy before being subjected to destructive mechanical tests. Information about a specimen’s microstructure and material properties will be used to develop and verify/validate the micromechanical model and Auditory Convolutional Neural Network. These two models will be used for optimization of the processing parameters. The flowchart of the proposed research is presented in Fig. 1. The proposed research will be done by an interdisciplinary team representing three universities from the state of New Mexico: New Mexico State University (NMSU), University of New Mexico (UNM) and New Mexico Institute of Mining and Technology (NMT). The team includes specialists in nondestructive testing and in-situ sensing, materials characterization, control and optimization, and micromechanical modeling. The proposed research has four technical and three non-technical objectives: Technical objectives 1. Develop and use in-situ sensing modalities for real-time process monitoring. 2. Determine the statistical correlations between microstructural defects, such as pores and microcracks, and processing parameters. 3. Develop a micromechanical model linking processing parameters with the overall properties of 3D-printed specimens. 4. Develop a real-time control system to modify and optimize the process parameters to minimize the concentration of microstructural defects. Non-technical objectives 1. Contribute to New Mexico aerospace engineering education and research programs; use these aerospace programs to engage New Mexico K-12 students in STEM disciplines. 2. Develop a statewide Research Center in Advanced Manufacturing and related areas such as verification and validation (V&V), modeling and simulation, damage prognosis and prevention. The Advanced Manufacturing research area and the aforementioned Research Center will be a primary focus for Workforce Development Programs. 3. Develop collaborations with aerospace industry and relevant NASA Centers, enhancing prospects for future nationally competitive research (see supporting letters).

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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.