SBIR-STTR Award

GeoComposites, LLC, aims to develop the next generation of high performance fiber reinforced composite feedstock for in-space manufacturing of high strength parts via fused deposition modeling (FDM). Since plastics are inherently low in strength, additive manufactured plastic currently cannot compete with metallic parts. Failed parts on the International Space Station (ISS) and the genuine need for structural spare parts onboard ISS and for deep space missions mandates that composite feedstock and associated FDM payloads should be developed for future in-space manufacturing. GeoComposites will develop composite feedstocks and associated deposition parameters to meet the requirement set by NASA for an ultimate tensile strength of 200 MPa. For a high strength part, it is not just sufficient to have a high strength feedstock but also a FDM facility that allows for the part build as dictated by the feedstock. GeoComposites proposes to demonstrate a combination of feedstocks for high strength parts. The part build will be performed with a dual nozzle FDM machine. The first feedstock will be created by extruding the mixture of a thermoplastic matrix with an optimized distribution of compatible chopped fibers. Continuity between the interlayer fibers will provide high bond strength between layers. The layup will combine this feedstock with continuous High Strength High Temperature (HSHT) fibers. Mechanical and outgas testing will be performed to demonstrate compatibility with NASA requirements. In addition, we propose to analyze ISS accommodation of FDM equipment capable of printing structural parts on the ISS using the developed feedstocks. The overall proposed approach will provide a comprehensive solution to include development of the customized high strength feedstocks, layup pattern and build parameters, and an analysis of ISS accommodation for consistent in-space production of high strength composite parts. Potential NASA Applications High strength feedstocks and an ISS-compatible FDM machine will provide the path for: · In-space manufacturing of structures, electronics, and tools; · Printed satellites, including CubeSats; · Mass savings on Space Launch Systems by replacing metallic parts with composites; · Printing of multifunctional radiation shielding material for crew health; · In-space part design using digital twins validated by real time diagnostics; · On-demand printing of food using cellulose based feedstocks. Potential Non-NASA Applications Non-NASA applications of FDM using high strength feedstock is expected to include: · For the medical industry, products ranging from medical devices to cell culturing; · For the aerospace industry, items like GE’s commercial jet engine nozzle; · For construction, fiber reinforced building material feedstock and Contour Crafting; · For the automotive industry, lightweight printed composites to enhance fuel efficiency; · For the Department of Defense, on demand printed parts in theater of operation.

The Phase I results have demonstrated the feasibility of using FDM, optimized feedstock combinations, and composite architecture to produce high strength parts. During Phase II, this initial success will be expanded on for this overall technology to become a feasible candidate for ISS accommodation. Accordingly, during Phase II the FDM unit will be modified to meet ISS compatibility standards and a prototype of this unit will be developed. In addition, the composite architecture, fiber layup, and feedstock combinations down selected from Phase I will be further optimized to improve structural capability beyond what was already achieved during the Phase I effort. Advanced feedstocks will be further developed not only for enhancement of structural properties but also from the perspective of outgassing. The team recognizes that for a true structural part built on the ISS, it may not be possible to conduct comprehensive mechanical testing on ISS to validate the part itself. During Phase II, a comprehensive finite element modeling (FEA) approach will be undertaken to predict mechanical properties as a function of feedstock combination and composite configuration. This FEA model will be validated using extensive mechanical and fracture testing data. Such a validated model will be a useful tool to select feedstocks and composite architecture combinations prior to printing a part on the ISS. Sufficient testing of down selected feedstock combinations and composites will be conducted to develop at least an S basis design allowable. We also propose to pursue FDM printing of metallic parts and demonstrate the potential of using the same FDM unit to print both composite and metallic parts. Development of such a versatile FDM unit will be a significant contribution to enhance ISS or NASA’s FabLab capabilities by reducing the launch payload mass and reducing the footprint. Potential NASA Applications (Limit 1500 characters, approximately 150 words) Direct NASA applications include in-space and on demand manufacturing of critical components. It could directly support the requirements of NASA’s FabLab efforts. FDM technology and feedstocks can be used for multifunctional composite structural radiation shields for the protection of humans and electronics during deep space missions and structural components for space transportation vehicles. Potential NASA contractors include SpaceX, Boeing, Orbital-ATK, Lockheed, Bigelow Aerospace, etc. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) - Department of Defense: on-demand printed parts in theater of operation. - Automotive Industry: lightweight printed composites to enhance fuel efficiency. - Aerospace Industry: commercial fuselage and jet engine nozzle. - Construction Industry: fiber reinforced material feedstock for Contour Crafting - Medical Industry: products ranging from medical devices to cell culturing.-