3D Printing in Space: igus Linear Axes Manufacture Spare Parts in Zero Gravity

The maintenance-free drylin SAW linear axes are the central component of the 3D printer. They ensure precise printing results with adjustable bearings. (Source: AMIS-FYT)

During a parabola flight, microgravity occurs, similar to weightlessness in space. Ideal conditions to test the 3D printer. (Source: AMIS-FYT)

When booms for solar panels or satellite antennas are transported into space on a carrier rocket, they are subjected to high stresses. To simplify the complex transportation process and accelerate the manufacturing of the components, the student team AIMIS-FYT is working on a 3D printing process. In the future, structural parts should be manufactured directly in space. For experimental tests in zero gravity, the students built a 3D printer. They used the maintenance-free and lightweight drylin SAW linear axes—supported by igus—in the drive technology.

The current process of transporting devices into space is quite inefficient and expensive. This is because the structural parts are primarily designed to withstand the high stresses during the launch phase of a spacecraft. However, for their later operational lifespan, these structures are overdimensioned. Due to the high costs and limited space on a carrier rocket, alternative solutions are needed. The Munich-based student team AIMIS-FYT addressed this issue and, as part of their aerospace engineering studies, is working on a 3D printing process for cost-effective manufacturing in space. The students use photoreactive resin and UV light to harden the resin. For experimental tests of the process in zero gravity, a 3D printer had to be designed and built. In search of suitable drive technology, the engineers turned to the motion plastics specialist igus and found the drylin SAW linear axes. The linear modules are used in the two Z-axes and the X-axis of the printer, forming the central drive unit. The linear axes impress primarily with their low weight, as they are made of aluminum and maintenance-free sliding elements made of high-performance plastic. To reduce the play of the lubrication-free and dirt-resistant polymer linear guides, the aspiring engineers used adjustable bearings. To enable the filament to rotate as well, a compact robolink D rotary axis with a worm gear was installed in the printer.

Successful test series under real conditions

To test the printer and the process, the team applied for the FlyYourThesis! program of the European Space Agency (ESA) and received approval. Parabolic flights took place in November and December 2020. When the aircraft reaches the peak of its climb and then begins its descent, microgravity occurs—similar to weightlessness in space. This provides ideal conditions for a real test of the printer. “The linear axes always operated flawlessly during all experiments, so we were able to print a small rod and even small truss structures on each parabola,” reports Torben Schäfer from the AIMIS-FYT team.

Young engineers support from igus promotes innovative projects

Projects like AIMIS-FYT are supported by igus through the young engineers support (yes) program. With this university initiative, igus aims to support students, teachers, and researchers with free samples, university discounts, sponsorship, and assistance in developing innovative projects. More information about university support can be found at www.igus.de/yes.