Galactic Extrusion Manufacturing System for Space Structures
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Solution Overview
Problem
Current extrusion technologies for building or repairing structures in space face challenges with non-metallic materials, such as off-gassing in low-pressure/vacuum environments, contamination risks, and brittleness at cryogenic temperatures, limiting their applicability and effectiveness.
Innovation Solution
A galactic extrusion manufacturing system with a self-contained extruder assembly and interchangeable cartridges, including a diaphragm-separated building material cartridge and a dispensing control unit, enables programmable extrusion of various materials in different shapes, using a robotic arm-tether-crimper for attachment to space-bound vehicles and structures, with a resupply mechanism for cartridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If non-metallic materials (polymers) are used for extrusion in space, then building versatility is improved, but contamination risk increases due to off-gassing in low-pressure/vacuum environments
Solution Approach 1:
The patent introduces a controlled environment chamber as an intermediary between the extrusion process and the space environment. This chamber maintains atmospheric pressure and temperature control, preventing polymer off-gassing from contaminating the space environment while still allowing extrusion operations to proceed with versatile building materials
2Adaptability or versatility
If non-metallic materials are used for extrusion in space, then material selection flexibility is improved, but reliability decreases due to curing/cross-linking problems in vacuum and cold environments
Solution Approach 1:
The patent employs parameter changes by controlling temperature and pressure within the extrusion chamber to enable proper curing and cross-linking of polymers. The system can heat the chamber to facilitate curing reactions and maintain atmospheric pressure conditions that are conducive to reliable polymer setting, thereby ensuring reliability while maintaining material flexibility
3Strength
If metallic materials are used for extrusion in space, then structural strength is improved, but energy consumption increases due to requirement of high intensity energy source for plasticization and fusion
Solution Approach 1:
The patent replaces the conventional high-intensity energy source approach with a mechanical extrusion system that operates in atmospheric pressure. The extruder uses mechanical force to plasticize and extrude metallic materials through a die, eliminating the need for high-intensity heating while still achieving strong metallic structures through controlled mechanical deformation and layer bonding
4Ease of manufacture
If polymers are used for extrusion in space, then ease of extrusion is improved, but structural integrity worsens due to brittleness at cryogenic temperatures
Solution Approach 1:
The patent uses parameter changes by controlling the temperature of the extrusion chamber to remain above cryogenic levels during the extrusion process. This temperature control prevents the polymer from becoming brittle, maintaining both ease of extrusion and structural integrity. The system can also adjust curing parameters to create cross-linked structures that retain flexibility at lower temperatures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a controlled and versatile method for extruding building materials in space, overcoming material limitations by ensuring contamination-free and shape-specific extrusion, with on-command expulsion and tethering capabilities for built structures.
Implementation Method 1
a diaphragm separating internal chambers of the building material cartridge, a first internal chamber on a first side of the diaphragm, a first fill port connected to the first internal chamber
Implementation Method 2
the charge media is a gas or an incompressible liquid, and the first fill port is hermetically sealed or welded shut after being filled with the charge media
Data Source
AI summary
A galactic extrusion manufacturing (GEM) system for performing an extrusion process includes an extruder assembly for extruding building material during the extrusion process, and a connection system including a robotic arm-tether-crimper for attachment of the GEM system to space bound vehicles and/or structures in space or on orbit. The extrusion assembly includes an extruder head outfitted with multiple different heads for shaping the building material during the extrusion process, at least one power cartridge, and at least one building material cartridge containing the building material, wherein the power cartridge and the building material cartridge are removable and replaceable. Also provided are a building material cartridge for use with a GEM system or a dispensing control unit (DCU) to perform an extrusion process, and a smart extrusion system including a building material cartridge and a DCU.