A 3D printing rover system for on-site additive manufacturing

Abstract

A 3D printing rover system for on-site additive manufacturing, consisting of: a mobile chassis that supports the structure of the rover system and facilitates the movement of the rover system through terrain; a robotic arm with a 3D printing extruder configured for layer-by-layer additive manufacturing; a material storage and delivery system configured to store and feed printing materials to the 3D printing extruder; a control system with autonomous operating functions configured to: receive real-time feedback about the environment, Adjust print parameters independently and Navigate and position the rover for optimal printing locations; a sustainable energy system configured to provide continuous energy for the operation of the rover system; and a thermal management system that is operatively linked to the control system and regulates the temperature of key system components to ensure smoother operation.

Description

FIELD OF THE INVENTIONThe present disclosure relates to a 3D print rover system for on-site additive manufacturing. In particular, the present invention provides a rover system with 3D printing functions, in particular for space missions. It enables additive manufacturing on site, in which structures are created layer by layer directly at the site of use.BACKGROUND OF THE INVENTIONSpace research has long been limited by the transport of important equipment and structures from the earth. Traditional space missions require extensive pre-planning and enormous payload capacities to carry all possible tools, structures and substitutes, which greatly increases the complexity and cost of missions. The astronomical costs for transporting materials into the All-often tens of thousands of dollars per kilogram-are urgent to make on-site solutions.From the above discussion, it can be concluded that transporting prefabricated structures or tools from the earth is expensive and impractical due to weight and space constraints. Therefore, the present invention provides a rover system with 3D printing functions. This system uses local resources (e.g., regolite or other extraterrestial materials) or already transported materials to construct structures and tools on site to provide sustainability and conformability. Due to the possibility of building directly at the site of use, this rover system supports space missions, since the transport of prefabricated structures or tools from the earth is dispensed with.SUMMARY OF THE INVENTIONThe present disclosure relates to a 3D print rover system for on-site additive manufacturing. The 3D print rover system allows on-site additive manufacturing for space missions and is designed for additive manufacturing directly on off-the-ground surfaces. By combining advanced robotics, autonomous navigation, and 3D printing technologies, the rover creates structures and tools from local or transported materials and thus revolutionizes the capabilities of space missions.The present disclosure aims to provide a 3D print rover system for on-site additive manufacturing. The system comprises: a mobile chassis supporting the structure of the rover system and facilitating movement thereof through terrain; a robotic arm having a 3D print extruder for layer-by-layer additive manufacturing; a material storage and delivery system for storing and supplying the 3D print extruder with print materials; a control system having autonomous operational functions for receiving real-time environmental feedback, autonomous adjustment of print parameters, and navigation and positioning of the rover for optimal print positions; a persistent power system for continuously powering the rover system; and a thermal management system connected to the control system for regulating the temperature of important system components for smoother operation.An object of the present disclosure is to provide a 3D print rover system for on-site additive manufacturing.Another object of the present disclosure is to enable critical structures and tools to be manufactured in situ in space environments, thereby obviating the need to transport bulky prefabricated equipment from the earth.Another object of the present disclosure is to develop a fully autonomous robot system capable of navigating and operating in extreme extra-earth areas with minimal human intervention.Another object of the present disclosure is to provide a persistent and adaptive solution for space research through the use of local resources and advanced manufacturing techniques.In order to further clarify the advantages and features of the present disclosure, the invention will be explained in more detail with reference to specific embodiments that are illustrated in the accompanying drawings. These drawings illustrate only typical embodiments of the invention and are therefore not to be considered as limiting the scope thereof. The invention will be described and explained in more detail with reference to the accompanying drawings.BRIEF DESCRIPTION OF THE FIGURESThese and other features, aspects, and advantages of the present disclosure will become more fully understood when the following detailed description is read with reference to the accompanying drawings, in which like characters represent like parts throughout. The following applies here: FIG. 1 shows a block diagram of a 3D print rover system for on-site additive manufacturing. FIGS. 2A, 2B, and 2C are diagrams illustrating various views of the developed 3D print rover system according to an embodiment of the present disclosure.Those skilled in the art will also appreciate that the elements in the drawings are shown for simplicity and are not necessarily to scale. For example, the flowcharts illustrate the method using the key steps to improve understanding of aspects of the present disclosure. In addition, regarding the construction of the apparatus, individual or multiple components of the apparatus may be represented by conventional symbols in the drawings. The drawings may only show the specific details relevant to understanding the embodiments of the present disclosure in order not to obscure the drawings with details readily apparent to those skilled in the art after the present description.DETAILED DESCRIPTION:In order to aid in the understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and will be described in an comprehensible manner. However, the scope of the invention is not limited thereby. Changes and further modifications of the illustrated system, as well as further applications of the principles of the invention, are possible, as would normally occur to a person skilled in the art.It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be limiting thereof.References throughout this specification to "one aspect," "another aspect," or similar language mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the phrases "in one embodiment," "in another embodiment," and similar phrases in this specification may or may not refer to the same embodiment.The terms "comprises," "comprising," or other variations thereof are intended to cover a non-exclusive inclusion, such that a process or method comprising a list of steps may include not only those steps, but also other steps not expressly listed or inherent in that process or method. Likewise, the phrase "comprises... for" one or more devices, subsystems, elements, structures, or components does not exclude, without further limitations, the existence of other devices, subsystems, elements, structures, components, or additional devices, subsystems, elements, structures, or components.Unless otherwise defined, all technical and scientific terms used herein have the same meaning as understood by one of ordinary skill in the art. The systems, methods, and examples provided herein are for illustrative purposes only and are not to be considered limiting.Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.FIG. 1 shows a block diagram of a 3D print rover system ( 100) for on-site additive manufacturing.Referring to FIG. 1, the system (100) includes a mobile chassis (102) that supports the structure of the rover system and facilitates movement of the rover system through terrain; a robotic arm (104) having a 3D print extruder configured for layer additive manufacturing; a material storage and delivery system (106) configured for storing and delivering print materials to the 3D print extruder; an autonomous operational capability control system (108) configured to: receive real-time ambient feedback, autonomously adjust print parameters, and navigate and position the rover for optimal print positions; a persistent energy system (110) configured to continuously provide energy for operation of the rover system; and a thermal management system (112) operatively connected to the control system (108) and configured to regulate temperature of important system components to ensure smoother operation.In one embodiment, the mobile chassis (102) is integrated with: a propulsion system (102a) having a plurality of wheels connected to high torque electric motors for moving the rover and a suspension system for shock mitigation; and a navigation module (102b) comprising a series of navigation sensors operatively connected to an AI driver navigation module configured to detect and avoid obstacles and identify optimal crossing paths, wherein the sensors comprise LiDAR, cameras, and accelerometers, and wherein the navigation module is connected to a control system.In one embodiment, the robotic arm (104) mounted on top of the mobile chassis (102) includes multi-axis joints for precise motion and a temperature controlled 3D printing extruder (104a) for printing, wherein the robotic arm (104) further includes a nozzle (104b) configured for handling space-compatible materials such as polymers, metals, and composites, and a precision positioning mechanism (104c) for laminating.In one embodiment, the material storage and delivery system (106) is configured to: store raw materials for 3D printing, support both pre-transported and locally harvested extraterrestial materials, include sensors to monitor the material level, and provide a controlled material delivery mechanism for the 3D printing extruder.In one embodiment, the control system (108) includes processing units (108a) configured using pre-installed structural plans and AI algorithms for real-time parameter adjustment, the control system further including environmental condition sensors for real-time environmental monitoring and a real-time feedback mechanism (108b) for changing print speed, material flow, and layer thickness based on real-time data.In one embodiment, the control system (108) is also configured to stabilize the rover during the printing operation, use GPS and terrain analyses for precise positioning, adjust printing strategies based on the local material composition, and ensure structural stability under different extraterrestial surface conditions.In one embodiment, the persistent power system (110) includes: solar modules (110a) for power generation, high power batteries (110b) for energy storage, and a power management system (110c) configured to not shut down required components during inactive times.In one embodiment, the thermal management system (112) is further configured to regulate critical component temperatures, provide insulation from extreme external temperatures, reuse heat generated by internal components, and maintain optimal operating conditions for the system.In one embodiment, the system (100) also includes an automated maintenance subsystem (114) configured to: perform self-diagnostic procedures; clean and re-calibrate the 3D print extruder; implement redundancy in critical systems; and autonomously manage potential component malfunctions.The present invention relates to a 3D print rover system, a comprehensive system incorporating several sophisticated space mission technologies. The rover system includes a mobile chassis with advanced propulsion systems designed to traverse sophisticated off-the-road areas. The robotic arm equipped with a precision 3D pressure extruder can make structures layer by layer from different materials, including local regolite or pre-transported stocks. The key components of the proposed system include: autonomous navigation with AI-controlled obstacle detection; multiaxial robotic arm for precise 3D printing; integrated material storage and delivery mechanism; sustainable energy systems (solar and nuclear energy options); advanced thermal management; as well as real-time environmental feedback and adaptive control. The rover may construct habitates, tools, infrastructure, and spares directly on site, greatly reducing mission complexity and payload demand.FIGS. 2A, 2B, and 2C illustrate diagrams showing various views of the developed 3D print rover system according to an embodiment of the present disclosure.Referring to FIGS. 2A and 2B, the proposed system includes a mobile chassis that serves as a basis for rover and is configured for effective navigation and operation on a variety of extraterrestial terrains including rocky, sandy, and icy surfaces. It is designed for durability and reliability under the demanding conditions of space research. The drive system integrated into the chassis has long-lived wheels or chains that are driven by electric motors with high torque. This configuration guarantees excellent traction at low gravity or uneven surfaces, so that the rover remains stable and mobile on different terrains. To further improve its functionality, the chassis is equipped with a suspension system which absorbs shocks and vibrations and thus ensures a smooth movement even on uneven ground. For navigation, the chassis relies on a number of advanced sensors, including LiDAR, cameras, and accelerometers. These sensors cooperate with AI algorithms to detect obstacles and determine optimal movement paths. This combination of technologies allows the rover to adapt to its environment and navigate through demanding environments precisely and efficiently. The rover may autonomously adapt its route depending on terrain requirements or mission requirements, thereby minimizing the need for remote control from the earth, where communication delays may affect responsiveness.Referring to Figure 2C, the system is equipped with a robotic arm with multiaxial joints that provide it with the necessary precision and flexibility for accurate layered 3D printing. Its range of motion ensures that different angles and positions are reached, thereby enabling efficient and versatile printing operations. This degree of articulation is of critical importance for the creation of detailed and complex structures. The arm contains a 3D pressure extruder (as shown in circle in Figure 2C). This extruder melts the material and applies it in successive layers to the surface, thereby gradually building up the desired structure. The die of the extruder is designed for the processing of aerospace materials such as polymers, metals and composites. It is also equipped with advanced temperature and flow control systems to provide consistent and reliable output throughout the printing operation.The material storage and delivery system of the proposed rover system is an integral part of 3D printing applications. A storage compartment on board the rover is provided for storing the raw materials required for printing. These materials may vary depending on mission goals and resources. They can contain materials already carried by the earth or locally obtained resources such as marsregolite or moon dust, for example. The feed mechanism provides efficient and controlled feed of material to the extruder. This mechanism is designed for a continuous and uninterrupted supply of material, which is decisive for the smooth progress of the printing operation. Sensors are incorporated into the system to monitor the material level and dynamically adjust the feed rate. This monitoring function helps to avoid potential problems such as clogs or bottleneck and ensures seamless system operation.The rover system control system seamlessly integrates preinstalled construction plans. These construction plans can be adapted in real time to changed environmental conditions or mission-specific requirements. This flexibility provides the versatility of the system and the ability to meet different operating requirements. To ensure precision and efficiency, the rover utilizes advanced feedback mechanisms. Sensors continuously monitor various environmental conditions such as temperature, pressure and material composition. This constant data stream allows the system to make adjustments during operation. For example, the AI of the rover may adjust parameters such as printing speed, material flow, and layer thickness based on the obtained real-time feedback. Should the surface on which the rover operates be uneven, the system compensates for these irregularities to ensure structural stability of the printed object. In addition, the rover is equipped with AI-based algorithms that enable autonomous operation. These algorithms allow them to detect and avoid obstacles, navigate rough terrain, and identify optimal print locations. This combination of advanced AI and navigation functions ensures that the rover functions effectively even in demanding environments and fulfills its tasks precisely and reliably.A persistent power system relies on carefully selected power sources and efficient power management to ensure continuous operation in different environments. In sun-proximity missions, solar modules collect energy stored in high-performance batteries. These batteries provide a reliable source of energy and allow uninterrupted operation even during periods of non-direct solar radiation. In darker or colder environments, such as on the mondpolules or on the mars, compact nuclear reactors serve as a constant and reliable energy source and ensure that the energy requirement of the mission is met independently of the solar availability. To maximize energy efficiency, all system components are designed for minimum energy consumption. In inactive phases, unnecessary systems are shut down to save energy. Thus, the system can distribute resources more effectively and remain durable in the long term.Space environments are characterized by extreme temperature variations that can seriously affect sensitive components. To address this challenge, the system is equipped with a thermal management system that contributes significantly to maintaining the functionality of important parts of the rover. This system controls the temperature of critical components including extruders, controls and stock stores, thus ensuring optimum operation thereof under different conditions. To increase efficiency, the system recycles the heat generated by internal components whenever possible. In addition, insulation protects the rover from the extreme temperatures in space. These measures ensure that the rover functions reliably despite the demanding thermal conditions.The proposed 3D print rover system ensures efficiency and precision in off-the-ground environments. It initializes the print with positioning, with the rover system using GPS and terrain analyses to locate the intended construction site. On arrival, stabilizers may be used to ensure that the rover remains stable and precise during the printing process. This is critical to maintaining precision under the harsh and unpredictable conditions of space.The layer-by-layer production is the heart piece of the printing process. The robot arm of the system deposits the material in precise layers, following a preinstalled construction plan. This allows for the production of various structures, including habitats, radiation shields, tools or replacement parts, which are tailored to the respective mission requirements. This systematic approach ensures that each layer is placed precisely to form long-lived and functional objects.The rover system provides flexible material options to optimize resource usage. It can mix locally available materials such as regolite with binders to create robust structures. This approach significantly reduces the dependence of transported stocks and makes missions more persistent. Alternatively, when using spaceable polymers or metals, the rover extruder provides for precise melting and molding of the materials to meet the required specifications.Safety and maintenance are an integral part of the system functionality. The system is equipped with automated maintenance systems that allow self-diagnosis and repair, thus increasing operational safety. The extruder die may be cleaned or re-calibrated during longer print cycles to ensure consistent quality. Moreover, critical systems including the control unit and the power supply are designed redundantly in order to avoid malfunctions due to component errors. This integrated fail-safe ensures seamless performance during critical operations.The possible uses of the 3D pressure capacities of the rover system are manifold and mission-critical. A major application is the construction of astronautenhabitates using local materials to reduce the payload required from the earth. The rover may also produce infrastructure such as landing sites, radiation shields, and stock units for stores. Moreover, it enables the production of tools and replacement parts for repairs as required, which increases the flexibility and efficiency of the mission. These capabilities make rover an indispensable tool for persistent and autonomous out-of-ground survey.In a concrete embodiment, the rover measures 3.5 meters in length, 2.8 meters in width and 2.2 meters in height for a total weight of 450 kilograms. The chassis is made of a high-strength aluminum alloy and has a space-compatible insulation in order to ensure durability and environmental protection. Mobility is provided by a six wheel drive system with high torque engines, while the rocker suspension provides for flexibility to uneven terrain. The rover reaches a maximum speed of 5 kilometers per hour on level ground.In a further embodiment, the energy system of the rover is designed for efficiency and reliability. It has primary solar modules with a power of 3 kilowatts, a secondary compact nuclear reactor with a continuous power of 300 watts and a 10-kilowatts-hour lithium-ion battery as a backup. Its adaptive energy saving system reduces the power consumption in idle phases and thus optimizes the power consumption.In another embodiment, the robotic arm and 3D printing system are key components of the rover functionality. The six-axis robot arm has a range of 2.5 meters and can handle a payload of up to 20 kilograms at maximum extension. The printing mechanism includes a high precision nozzle that supports materials such as bulky polymers, composites, and regolite binders. The nozzle diameter is adjustable, with a standard size of 0.4 millimeters, and the system achieves a printing accuracy of ±0.1 millimeters. The material storage system has a capacity of 50 liters and the feed rate is adjustable from 0.1 to 5 kilograms per hour.In another embodiment, the control system is controlled by an AI-based unit having a 32-core processor. The navigation system includes LiDAR, cameras, and inertial measurement units (IMUs). An advanced obstacle avoidance system uses real-time feedback for route diversion. Autonomous rover functions include 3D terrain mapping that allows selection of optimal navigation paths and print locations as well as real-time optimization of print parameters based on environmental feedback.In another embodiment, the rover is designed to withstand extreme conditions. It can be operated without problem in a temperature range from -150° C. to +12° C. and has completely closed systems for dust reduction. The electronics are shielded from high radiation and thus ensure functionality even in demanding off-the-ground environments.In a further embodiment, maintenance and safety are integral components of the rover system. The nozzle is automatically cleaned and re-calibrated during longer print cycles. The system has self-diagnostic functions for detecting hardware and software problems. Redundant power supply and control systems provide additional reliability and provide continuous operation at critical missions.A typical application for rover is, for example, the construction of habitates on the moon. The process begins with the rover being transported to the intended location with a lander. After exposure, it autonomously navigates to a planar surface and employs stabilizers. The robot arm is then activated and the extruder applies a regolite-based mixture layer by layer. Integrated sensors monitor the process and adjust layer thickness and material flow as required. The finished habitat structure is designed to withstand the harsh conditions of the moon environment.The 3D pressure rover system is based on the principle of additive manufacturing on site, in which structures are built up layer by layer directly at the site of use. This technology is particularly important for space missions where transporting prefabricated structures or tools from the earth is both expensive and impractical due to weight and space constraints. By using local resources such as regolite or other extraterrestial materials or already transported materials, the rover can produce structures and tools on site and thus ensure sustainability and adaptability to different mission requirements. This approach greatly reduces the dependence on earth supply and improves the feasibility of long term space research.The rover system combines mobility, endoscopy, and 3D printing technology into a single, versatile device. It utilizes advanced energy management systems and environmental feedback mechanisms to function effectively even under extreme conditions, such as those encountered on the moon or mars. Its design is designed to drive over uneven terrain, withstand extreme temperatures, and operate without continuous human monitoring. These capabilities make rover an indispensable tool for future space missions, particularly in environments with considerable logistic and operational challenges.The 3D print rover system consists of several key components that enable its functionality. It has a mobile chassis with drive systems optimized for off-road terrain, which ensure smooth navigation on demanding surfaces. A multiaxial robot arm enables precision-based additive manufacturing, so that the rover can create structures with high accuracy. In addition, the rover is equipped with a material storage and delivery system designed for use with spaceable materials, which further enhances its versatility. The control system has programmed autonomy and real-time environmental feedback so that the rover can bypass obstacles and dynamically adjust its operation. The rover is operated with lasting energy sources such as solar or nuclear energy and has a thermal management system which ensures reliable operation even at extreme temperatures.The 3D print rover system represents a path-breaking technology for space research. By combining advanced robotics, additive manufacturing, and smart control systems, it provides an innovative solution to the challenges in building and maintaining infrastructure on extraterrestial surfaces. The ability of the rover system to autonomously and efficiently build structures reduces logistic effort, increases mission flexibility, and levels the way for long-term colonization on Moon, Mars, and beyond. Its persistent and customizable design ensures that it will play a decisive role in the future of space research and offer new possibilities for space research and colonization.The drawings and the foregoing description show examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be divided into multiple functional elements. Elements of one embodiment may be added to another embodiment. For example, the order of the processes described herein may be changed and is not limited to the manner described herein. Moreover, the actions of a flow chart need not be performed in the order shown; nor do all actions necessarily need to be performed. Also, actions that are not dependent on other actions may be performed in parallel with the other actions. The scope of the embodiments is by no means limited by these specific examples. Numerous variations, whether or not explicitly stated in the specification, such as differences in structure, dimensions, and material use, are possible. The scope of the embodiments is at least as broad as recited in the following claims.Advantages, other advantages and solutions to problems have been described above with reference to specific embodiments. However, the advantages, merits, solutions to problems and any components that may result in an advantage, merit or solution being introduced or enhanced are not to be understood as critical, required or essential features or components of individual or all claims.REFERENCES100- A 3D Print Rover System For Die Additive Manufacturing In Situ. 102 Wheeled chassis 102 aDrive system 102 b Navigations module 104 Robot arm 104 aTemperature controlled 3D pressure extruder 104 bNozzle 104 cPrecision positioning mechanism 106 Material storage and delivery system 108 Control system 108 a Verarbeitungs units 108 b Echtzeit feedback mechanism 110 Persistent power system 110 a Solarmodul modules 110 b Hochleistungs batteries 110 cPower management system 112 Thermal management system 114 Automated maintenance subsystem

Claims

A 3D print rover system for on-site additive manufacturing, comprising: a mobile chassis that supports the structure of the rover system and facilitates movement of the rover system through terrain; a robotic arm having a 3D print extruder configured for layer-by-layer additive manufacturing; a material storage and delivery system configured to store and deliver print materials to the 3D print extruder; a control system having autonomous operational functions configured to: obtain real-time feedback to the environment, adjust print parameters independently, and navigate and position the rover for optimal print locations; a persistent power system configured to continuously provide power for operation of the rover system; and a thermal management system operatively connected to the control system and regulating the temperature of important system components to provide smoother operation.The system of claim 1, wherein the mobile chassis is integrated with: a multi-wheel drive system connected to high torque electric motors for rover motion and a suspension system for shock mitigation; and a navigation module comprising a series of navigation sensors operatively connected to an AI driver navigation module configured to detect and avoid obstacles and identify optimal crossing paths, wherein the sensors comprise LiDAR, cameras, and accelerometers, and wherein the navigation module is connected to a control system.The system of claim 1, wherein the robotic arm mounted on top of the mobile chassis comprises multi-axis joints for precise movement and a temperature controlled 3D printing extruder for printing, the robotic arm further comprising a nozzle configured for handling spaceable materials such as polymers, metals and composites, and a precision positioning mechanism for laminating.The system of claim 1, wherein the material storage and delivery system is configured to: store raw materials for 3D printing, support both pre-transported and locally-obtained extra-terrestrial materials, include material level monitoring sensors, and provide a controlled material delivery mechanism for the 3D printing extruder.The system of claim 1, wherein the control system comprises processing units configured using pre-installed structural plans and AI algorithms for real-time parameter adjustment, the control system further comprising environmental condition sensors for real-time monitoring of the environment; and a real-time feedback mechanism for changing the print speed, material flow, and layer thickness based on real-time data.The system of claim 1, wherein the control system is further configured to stabilize the rover during the printing operation, use GPS and terrain analyses for precise positioning, adjust printing strategies based on the local material composition, and ensure structural stability at different extraterrestial surface conditions.The system of claim 1, wherein the persistent power system comprises: solar modules for power generation; high power batteries for energy storage; and a power management system configured to shut down not necessarily required components during inactive times.The system of claim 1, wherein the thermal management system is further configured to regulate critical component temperatures, provide insulation from extreme external temperatures, reuse heat generated by internal components, and maintain optimal operating conditions for the system.The system of claim 1, further comprising an automated maintenance subsystem configured to: perform self-diagnostic procedures; clean and re-calibrate the 3D print extruder; implement redundancy in critical systems; and autonomously manage potential component malfunctions.

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