SBIR-STTR Award

This program will develop an in-space material manufacturing approach to leverage the unique capabilities of the International Space Station. Specifically, one such, exemplar novel class of material, covetics (nano-carbon-infused metals), are inherently challenging to produce terrestrially but have great commercial potential due to their enhanced physicochemical properties as compared to conventional metals, such as high thermal (50% higher than Cu), high electrical conductivity (40% higher than 6061 Al), and high strength (30% higher yield strength than Cu). Therefore, Faraday Technology and the University of Texas in Dallas will develop a material manufacturing process to directly print these next generation covetic materials in Low Earth Orbit (LEO) via an electro-codeposition approach. This work will build on the University of Texas's direct Cu printing platform which has been demonstrated at pre-commercial scale the potential to print large area circuit board lines utilizing a localized pulse electrodeposited (L-PED) technique. Additionally, this work will build on Faraday’s electro-codeposition process activities that include depositing carbon materials into copper. In Phase I we will establish the viability of directly printing covetic materials by developing the direct write hardware and the electro-codeposition electrolytes to deposit electrochemically reduced carbon materials into a copper matrix in an orientation opposite or perpendicular to gravity such that we can demonstrate at the lab scale, the potential to form covetic materials with enhanced electrical, thermal, and mechanical properties. This demonstration would enable a preliminary market need assessment (Phase I) and zero gravity flight demonstration (Phase II), which could establish a commercial market for in-space manufacturing of these exciting covetic materials. If successful the results of the Phase I/II program will set the stage for LEO commercialization of this manufacturing process. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Next generation materials like covetics have the potential to meet many of NASA continual needs on-board the space station and within their spacecraft systems. These materials could be utilized to make spot structural repairs, be printed in to forms like electronic components (i.e., resistor or capacitors), or be utilized as heat exchange materials. Regardless, an approach to on-demand manufacturing of state of the art materials and components on-board the ISS has a wide commercial impact. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): At the successful completion of this program, we envision our initial entry point for the technology will be the electronics industry (communications, computers, satellites, etc.) due to their need for lightweight high conductivity materials. The second market will focus on the transportation sectors, who strive for high strength to weights ratios. Duration: 6

An on-demand direct metal printing technology will be developed that can utilize the unique advantages of manufacturing in a zero-gravity Low Earth Orbit (LEO) environment, to produce value-added next generation materials that are challenging to manufacture terrestrially. One such class of materials, covetics (nanocarbon-infused metals), are inherently difficult to produce on Earth but have great in-space and terrestrial commercial potential due to their enhanced physicochemical properties, such as higher thermal/electrical conductivity and higher strength at lower mass as compared to conventional wrought metals. This program will develop the technical capabilities of the direct print method and module to print covetic materials on-demand in an LEO environment with the desired material property enhancements. Alignment with NASA and commercial space needs, and acceleration of integration of the technology into NASA’s mission, will be done by designing and building a direct print module and method can be incorporated into nScrypt’s multi-module platform, for subsequent demonstration in a parabolic loop zero-gravity flight test. (Note: the nScrypt multi-module system is the same that NASA’s On-Demand Manufacturing of Electronics group is installing on the International Space Station in FY2024). A successful demonstration of the direct print method and module’s viability through the zero-gravity flight test will align the covetic manufacturing technology with space approved hardware and reduce the entry barrier toward LEO demonstration in Phase IIE/III. Finally, the commercial viability will be established by outreach to the communities interested in covetic material properties and by identifying a pathway to system scale and implementation on commercial space platforms. As the market value is validated and technical method is demonstrated on International Space Station, we will work with commercial space companies (Axiom Space) to scale and transition the technology. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Next generation materials like ‘covetics’ have the potential to meet many of NASA’s needs on-board the International Space Station and in spacecraft systems. These materials have high thermal and electrical conductivity and high strength, and could be utilized to make spot structural repairs, be printed into forms like electronic components or sensors, or be utilized as heat exchanger materials. An approach for on-demand manufacturing of covetic materials and components on-board the ISS has a wide potential impact on NASA logistics and safety. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Two early adopter markets for nano-carbon infused metals (covetics) are thermal management solutions and electronics maintenance/repair. Both terrestrial and in-space commercial applications, e.g., space stations and satellites, could benefit from next-generation materials. In 2020 the thermal management market was $8.8B, while the electronic repair market was $15B, both growing at a CAGR of 8%. Duration: 24