Session
Session XII: Advanced Technologies II
Location
Utah State University, Logan, UT
Abstract
Additive manufacturing in space has been recognized as one of the required technologies for space colonization and deep space exploration. The current state of the art indicates that efforts are being done to achieve 3D (Three Dimensional) printing in space, in particular, inside the International Space Station (ISS) in a controlled environment. However, no spacecraft has performed additive manufacturing tasks in open outer space subject to the vacuum, reduced gravity and the extreme temperatures. In this work, a 1U small satellite, nicknamed Orbital Factory II (OFII) will perform a technological demonstration of 3D printing of conductive material. The small satellite features a 3D printing 2-DOF gantry table mechanism that will deposit conductive ink and simulate repairing of a solar cell. The material to 3D print was selected based on bulk resistivity, viscosity and amount of conductive particles, as well as curing time and low outgassing. Up to date, vacuum test has determined that the ink will cure in space after 90 secs and as a such will be conductive after that period of time. A VGA camera and sensor measurements will determine the mission success. Taking advantage of the fact that we house a world-class additive manufacturing center, some of the satellite’s parts have been 3D printed in ProtoThermTM 12120 (Three Dimensional), which is a polymer to produce high-temperature tolerant and liquid resistance parts by SLA process. The satellite also includes an S-band patch antenna as a secondary payload. The antenna was entirely designed and built by Lockheed Martin Co. We tested and characterized the antenna and finally integrated into our CubeSat. Since the gain pattern of the S-band antenna is narrow, an attitude controller based on magnetorquers will be implemented to ensure proper pointing to the Earth. Up to now, vibration test, reveals that our payload will withstand the lunch environment given by our lunch provider (NanoRacks). We have also confirmed that due to the small amount that will fly and low outgassing properties of the ink, our payload does not represent any risk during launch and its deployment. Finally, the satellite is scheduled to be launched at the end of this year in an Antares rocket from Wallops and deployed either from a Cygnus spacecraft or the ISS. The full paper will show the design, integration, and the different test and corresponding results performed to the OF-2 satellite.
Orbital Factory 2: A 1U CubeSat for Additive Manufacturing Tasks in Low Earth Orbit
Utah State University, Logan, UT
Additive manufacturing in space has been recognized as one of the required technologies for space colonization and deep space exploration. The current state of the art indicates that efforts are being done to achieve 3D (Three Dimensional) printing in space, in particular, inside the International Space Station (ISS) in a controlled environment. However, no spacecraft has performed additive manufacturing tasks in open outer space subject to the vacuum, reduced gravity and the extreme temperatures. In this work, a 1U small satellite, nicknamed Orbital Factory II (OFII) will perform a technological demonstration of 3D printing of conductive material. The small satellite features a 3D printing 2-DOF gantry table mechanism that will deposit conductive ink and simulate repairing of a solar cell. The material to 3D print was selected based on bulk resistivity, viscosity and amount of conductive particles, as well as curing time and low outgassing. Up to date, vacuum test has determined that the ink will cure in space after 90 secs and as a such will be conductive after that period of time. A VGA camera and sensor measurements will determine the mission success. Taking advantage of the fact that we house a world-class additive manufacturing center, some of the satellite’s parts have been 3D printed in ProtoThermTM 12120 (Three Dimensional), which is a polymer to produce high-temperature tolerant and liquid resistance parts by SLA process. The satellite also includes an S-band patch antenna as a secondary payload. The antenna was entirely designed and built by Lockheed Martin Co. We tested and characterized the antenna and finally integrated into our CubeSat. Since the gain pattern of the S-band antenna is narrow, an attitude controller based on magnetorquers will be implemented to ensure proper pointing to the Earth. Up to now, vibration test, reveals that our payload will withstand the lunch environment given by our lunch provider (NanoRacks). We have also confirmed that due to the small amount that will fly and low outgassing properties of the ink, our payload does not represent any risk during launch and its deployment. Finally, the satellite is scheduled to be launched at the end of this year in an Antares rocket from Wallops and deployed either from a Cygnus spacecraft or the ISS. The full paper will show the design, integration, and the different test and corresponding results performed to the OF-2 satellite.
