TY - CONF A1 - Meyer, Lena T1 - Powder based Additive Manufacturing in Space N2 - Abstract of the event: 'The area of New Space is a vastly growing and dynamic field with a high innovative potential and many exciting ideas. After decades where activities in space were dominated and funded mainly by governmental agencies, a new industry is forming and new business models are being developed around ideas like satellite-based internet, space travel, space mining, geo-monitoring etc. For space applications, lightweight design is crucial to keep the costs at a minimum. This Innovation Day will introduce the field of New Space and present the variety of exciting opportunities that arise for composites based on their excellent lightweight potential.' Another research area is now arising in the field of 3D printing or additive manufacturing of fiber composite materials in space. At the event, we presented on the opportunities and our experiences of using a powder based additive manufacturing process for in-space manufacturing applications. T2 - CU Innovation Day - New opportunities and applications in space with composites CY - Online meeting DA - 29.03.2022 KW - μ-gravity KW - In-space manufacturing KW - Additive manufacturing KW - Microgravity KW - Powder PY - 2022 AN - OPUS4-54559 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Clozel, Melanie A1 - Neumann, Christian A1 - Thore, Johannes A1 - Kolbe, Matthias A1 - Yang, Fan A1 - Gutowski, Olof A1 - Dippel, Ann-Christin A1 - Ruschel, Lucas M. A1 - Busch, Ralf A1 - Altenbach, Christoph A1 - Akuata, Chijioke Kenneth A1 - Zander, Daniela A1 - Wilbig, Janka A1 - Meyer, Andreas T1 - Microstructure formation during gas flow-assisted additive manufacturing of a metallic glass powder on ground and in microgravity N2 - We studied bulk metallic glasses produced from gas flow-assisted laser-based powder bed fusion process, which is capable of additive manufacturing metallic parts in microgravity. A Zr-based bulk metallic glass composition Zr₅₉ˏ₃Cu₂₈ˏ₈Al₁₀ˏ₄Nb₁ˏ₅ has been processed on ground and in microgravity in a compact sounding rocket payload MARS-M. Microstructure characterization was performed using electron microscopy and X-ray diffraction computed tomography, which cope with small amounts of sample materials, especially for those fabricated under microgravity conditions. Very similar microstructures and crystalline fractions are observed in sample manufactured on ground and in microgravity, which shows that process parameters of conventional laser powder bed fusion for manufacturing metallic glasses can be transferred to the processes in microgravity. Two different origins of crystallization have been identified in the Zr₅₉ˏ₃Cu₂₈ˏ₈Al₁₀ˏ₄Nb₁ˏ₅ sample. The preferred occurrence of CuZr₂ at the interlayer boundaries is likely a result of recrystallization from the undercooled melt and hence associated with laser scanning strategy. In contrast, the more uniformly distributed Al₃Zr₄ phase is considered to be triggered by the formation of Cu₂Zr₄O. Thus, for the fabrication of fully amorphous builds both on ground and in space, our findings point to higher scanning speeds and lower oxygen contents, while the latter can also be used to tune the crystalline fractions in the sample. KW - Gas flow-assisted laser-based powder bed fusion KW - Microgravity KW - Glass-forming alloys KW - X-ray diffraction tomography PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-641253 DO - https://doi.org/10.1007/s40964-025-01275-2 SN - 2363-9512 SP - 1 EP - 14 PB - Springer Science and Business Media LLC CY - Cham, Switzerland AN - OPUS4-64125 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Meyer, Lena T1 - Laser beam melting additive manufacturing at μ-gravity N2 - In-space manufacturing (ISM) provides the opportunity to manufacture and repair critical components on future human spaceflight missions. For explorations to Mars and beyond, ISM is a key strategy not only due to the long travel distances and high costs of supply from earth but also to be able to safely work in space for years. Human spaceflight is still dependent on shipments from earth that can fail for several reasons. ISM is a valuable alternative to ensure the timely and safe resupply of space missions. With additive manufacturing (AM) technologies, components are built directly from a 3D computer-aided-design (CAD) model which offers the advantages of freedom of design and the production of complex and ready-to-use parts. A virtual tool box with 3D models in space or the supply of information instead of components from earth to space can strongly benefit future missions. For industrial use, most research has focused on laser based additive manufacturing processes such as laser beam melting (LBM) where metallic powder particles are spread into a uniform powder bed and melted by a laser to the desired shape. In the absence of gravity, the handling of metal powders, which is essential for the process, is challenging. We present an evolution of an AM system, where a gas flow throughout the powder bed is applied to stabilize the powder bed. This is needed to compensate for the missing gravitational forces in microgravity experiments on parabolic flight campaigns. The system consists of a porous building platform acting as a filter for the fixation of metal particles in a gas flow. It is driven by reduced pressure established by a vacuum pump underneath the platform. The system creates a drag force that directs the particles towards the porous building platform, similar to the effect of the gravitational force. The AM system with its gas-flow-assisted powder deposition has been tested in several parabolic flight campaigns, and stainless-steel powder has successfully been processed during microgravity conditions. Different powder recoating mechanisms have been investigated to assess the homogeneous distribution of the powder as well as the attachment of the next layer to the powder bed. These mechanisms included different container designs with parallel double blades and with a V-shape at the bottom, and a roller recoating system. The samples presented are the first metal parts ever manufactured using LBM in μ-gravity. In addition to manufacturing in a μ-gravity environment, the experiments have shown the feasibility to manufacture components at different accelerations during the parabolic flight: hyper gravity (1.8 g), μ-gravity (< 0.01 g) and 1 g. Recent results will also be presented describing the application of this LBM setup in a parabolic flight campaign with mixed lunar, martian and µ-gravity acceleration, during which the processing of a lunar regolith simulant powder was tested. For ISM, the development and testing of the proposed AM system demonstrates that LBM can be considered a viable technology for the manufacturing of metal and ceramic parts in a μ-gravity or reduced-gravity environment. T2 - International Conference on Advanced Manufacturing CY - Online meeting DA - 07.03.2022 KW - μ-gravity KW - In-space manufacturing KW - Additive manufacturing KW - Laser beam melting KW - Microgravity KW - Stainless steel KW - Lunar regolith simulant PY - 2022 AN - OPUS4-54450 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günster, Jens T1 - Laser beam melting additive manufacturing at μ-gravity N2 - At the Workshop "Neutron and Synchrotron Monitoring in Aerospace Advanced Manufacturing" at the Institute of Materials Physics in Space, German Aerospace Center (DLR) in Cologne, we presented on the opportunities and our experiences of using a powder based additive manufacturing process for in-space manufacturing applications in microgravity. T2 - Workshop 'Neutron and Synchrotron Monitoring in Aerospace Advanced Manufacturing' CY - Cologne, Germany DA - 11.08.2022 KW - Additive manufacturing KW - In-space manufacturing KW - Microgravity KW - μ-gravity KW - Laser beam melting KW - Advanced manufacturing KW - Aerospace KW - Process monitoring PY - 2022 AN - OPUS4-56521 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kolsch, Nico T1 - Enabling online quality control of powder deposition for 3d printing in microgravity N2 - 3D printing or additive manufacturing in space is of great value for long-term human spaceflight missions and space stations, conveniently offering access to a ‘virtual warehouse’ of tools and spare parts on the push of a button. The process only needs one type of feedstock such as powder or filament and only as much material as the final part requires, giving it a huge weight benefit over traditional subtractive methods. While 3D printers are already operational on the ISS since 2014, the utilized processes are only capable of manufacturing relatively low strength parts from polymers not suitable for many tools or critical components. To gain access to high quality metal prints, a modified Laser Powder Bed Fusion (LPBF) process was developed to stabilize the critical powder bed in microgravity through a gas flow [2]. This setup was able to generate a (miniature) steel wrench during parabolic flights, but a reliable layer deposition has raised challenges due to the combination of gas flow parameters with microgravity conditions. Furthermore, the quality and density of the powder bed, which is critical for the process, cannot be examined afterward on the ground. This is due to hyper gravity phases during the flight that are influencing the properties of the powder bed. In this paper, the challenges of the layer deposition are revised, and the subsequent evolution of the recoating system explained. Later, the challenges of an in-situ quality control, evaluation, and quantification of the properties of the powder bed are examined. As a solution, a high-resolution line-scanner is proposed and its implementation int the compact LPBF system demonstrated. Its ability to measure common defects such as ridges in the deposited layer is shown in experiments at normal gravity. As an illustration, Figure 1 shows an extreme case of the formation of ridges. T2 - European Conference on Spacecraft Structures Materials and Environmental Testing CY - Toulouse, France DA - 28.03.2023 KW - Additive manufacturing KW - In-space manufacturing KW - Online quality control KW - Microgravity KW - Powder deposition PY - 2023 AN - OPUS4-57249 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Meyer, Lena T1 - 3-D Druck in Schwerelosigkeit – Patentanmeldung für den Bau für Werkzeug und Ersatzteilen im Weltall N2 - Präsentation der Aktivitäten an der BAM im Bereich 3-D Druck in Schwerelosigkeit. T2 - Besuch des Deutschen Patent- und Markenamtes DPMA München CY - Berlin, Germany DA - 19.07.2022 KW - Additive manufacturing KW - Microgravity KW - Patent KW - Powder KW - Additive Fertigung KW - 3D Druck KW - Schwerelosigkeit PY - 2022 AN - OPUS4-56314 LA - mul AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -