Scientists Create New Technique for 3D Printing in Microgravity

Space has always fascinated humanity, and the colonization of Mars and the Moon remains a major goal. To achieve this, it is necessary to process local resources under the conditions present there. 3D printing shows impressive potential in this area, as repairs can be carried out directly with minimal material usage, avoiding the need for expensive spare parts. Numerous projects and research efforts are exploring 3D printing in microgravity, each advancing space exploration and the use of additive manufacturing in orbit. Now, two German universities have contributed by developing a flexible method for laser additive manufacturing in microgravity.

An interdisciplinary research team from Leibniz University Hannover (LUH) and Otto von Guericke University Magdeburg collaborated on the project “Additive Manufacturing in Microgravity Using Laser Metal Deposition”, funded by the German Research Foundation. As part of the project, the researchers developed a flexible 3D printing method for producing and repairing metal components under microgravity conditions. The process uses laser metal deposition with metal powder, where a laser selectively melts the powder, building up the component layer by layer. The method can also be used to repair existing parts by printing directly onto the damaged area.

Marvin Raupert, project engineer, pictured with a model demonstrating the 3D printing process.

The team’s biggest challenge was handling the powder and processing it in microgravity. To simulate these conditions, the Einstein Elevator was used. This large-scale research device, located at the Hannover Institute of Technology, allowed the researchers to test the printing process under different gravitational conditions. These conditions ranged from weightlessness to the intense forces experienced during a rocket launch. The powder delivery system and the laser system were installed in a gondola and adapted to the microgravity environment of space. The researchers tested laser metal deposition with various materials, including titanium and nickel alloys, both popular in additive manufacturing for aerospace applications.