Automated Additive Manufacturing Inspection, Detection, and Repair for Space Structures (AAMIDRSS)

Automated Additive Manufacturing Inspection, Detection and Repair for Space Structures (AAMIDRSS) will develop an automated defect inspection, detection, and repair (IDR) demonstration for wire-based additive manufacturing (AM) to enable in-space manufacturing (ISM) and a sustained human presence beyond low earth orbit (LEO) by improving confidence in the production and repair of critical components and structures. The system will have sensors mounted on the AM tool capable of detecting common AM defects in newly made or repaired parts. Software will autonomously process the defect data acquired from the parts and determine the defect types and criticality to the parts' structural integrity. The system will determine the best corrective action (if any) and issue repair commands to the AM system to perform a repair action. A final scan will be performed to verify that the repair was successful. Currently, most terrestrial additively manufactured parts for use in-space require strict process control in addition to the printing of large numbers of test samples for characterization and mechanical testing to ensure quality (see NASA-STD-6030). Process monitoring systems exist for some AM processes to flag potential defects but require human-in-the-loop for IDR. Similarly, in-space IDR of damaged parts are performed by astronauts using up precious time or requiring risky extravehicular activity. Automating IDR would improve the quality of AM parts made without direct human supervision and increase the reliability of AM part for both ISM and on-Earth manufacturing. Additionally, the technology decreases the need for human intervention, paving the way for autonomous manufacturing and repair of space structures in remote locations. The technology offers a multitude of potential savings in protecting valuable astronaut's time, decreasing mission risks by maintaining assets, decreasing the need for costly launches of replacement and spare parts, enabling reliable AM (both in-space and terrestrially), and broadening of mission design space with the ability for parts to be manufactured and repaired. Furthermore, the data collected forms a digital record that can be leveraged towards a digital twin.

​AAMIDRSS is directly addressing the need for autonomous manufacturing, inspection, and repair in space and on the surface of other planetary bodies (Moon to Mars Architecture – LI-4L; Taxonomy - TX12.4.1; STMD Shortfall - #1487, #1534) to maintain a continuous robotic and human presence. To manufacture reliable components beyond Earth, robust NDE sensors are required to provide data to be autonomously analyzed and output commands for quantification and characterization of newly manufactured components and repaired structures (TX10.1.1; TX12.4.5; STMD Shortfall #1486, #1494). Additionally, the astronaut’s utility and time will be maximized by automating and removing tedious and time-consuming tasks involving manufacturing, inspection, and repair that will be required to create a robust, sustained human/robot presence beyond earth (Moon to Mars Architecture – OP-9LM). Additionally, the technology can be utilized by the terrestrial additive manufacturing and welding industries in order to enable increased reliability and autonomy for use cases in remote or hazardous environments.

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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