3D printing in space: igus linear axes produce spare parts in weightlessness

When booms for solar panels or satellite antennas are transported into space in a launcher, they are subjected to large loads. To simplify the complex transport and speed up the production of the elements, the To AIMIS-FYT student team is working on a 3D printing process. In the future, it should be possible to produce structural parts in space. To conduct experimental tests in weightlessness, the students built a 3D printer. For the drive technology supported by igus, they relied on the maintenance-free and lightweight drylin SAW linear axes.

The current process for transporting equipment to space is quite inefficient and expensive. This is because the structural parts are primarily designed to withstand the high loads during the launch phase of a spacecraft. However, these structural parts are oversized for the subsequent period of use. Due to high costs and limited space on a launcher, alternative solutions are needed. The Munich-based student team AIMIS-FYT tackled the problem and is working on a 3D printing process for cost-effective production in space as part of their aerospace engineering degree program. To do this, the students are using photoreactive resin and UV light, which hardens the resin. A 3D printer had to be designed and built for experimental testing of the process in a weightless state. In their search for the right drive technology, the engineers turned to motion plastics specialist igus and found what they were looking for in the drylin SAW linear axes. The linear modules are used in the two z-axes and in the x-axis of the printer, forming the central drive unit. The linear axes are particularly impressive for their low weight because they are made of aluminum and maintenance-free sliding elements made of high-quality polymer. To reduce backlash from the lubrication-free and dirt-resistant polymer linear guides, the would-be engineers resorted to adjustable bearings. To ensure that the print filament could also be rotated, a compact robolink D rotary axis with worm gear was installed in the printer.

To test the printer and process, the team enrolled in the European Space Agency's (ESA) FlyYourThesis! program and was accepted. The parabolic flights took place in November and December 2020. When the aircraft reaches the peak of its ascent and tilts into descent flight, microgravity occurs, very similar to weightlessness in space. Ideal conditions for a real test of the printer. "The linear axes worked smoothly in all experiments, and so we were able to print a small rod and also small framework structures at each parabola," Torben Schäfer of the AIMIS-FYT team reports with satisfaction.

Projects such as AIMIS-FYT are supported by igus as part of the "young engineers support" (yes) program. With the university initiative, igus aims to support pupils, students and teachers with free samples, university discounts and sponsorships and the development of innovative projects. For more information on igus support for universities, visit www.igus.eu/yes.