On-Orbit Additive Manufacturing Thermal and Contamination Control
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Solution Overview
Problem
Additive manufacturing in space environments with near vacuum pressure and zero-g force poses challenges in thermal control and contamination control, particularly with regards to maintaining temperature ranges and preventing volatile organic compounds (VOCs) from affecting spacecraft components.
Innovation Solution
Incorporating a thermal control arrangement using phase change material (PCM) modules and a contamination control arrangement with a chamber and cold plates to maintain temperature and capture VOCs, along with a robotic manipulator for module replacement and vent path design to avoid net torque, enabling additive manufacturing on spacecraft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is performed in space environment, then custom service articles can be fabricated on-orbit, but thermal control becomes difficult due to near vacuum pressure and zero-g force
Solution Approach 1:
The thermal control arrangement is divided into multiple independent PCM modules that can be individually positioned and configured. Each module contains phase change material encapsulated in a container with thermal mass, allowing distributed thermal management throughout the additive manufacturing system rather than relying on a single centralized thermal control mechanism.
Solution Approach 2:
The invention utilizes phase change material (PCM) that undergoes phase transitions (solid-liquid-crystal) at specific temperatures to absorb and release thermal energy. The PCM modules maintain temperatures within specified ranges by leveraging these phase transitions, which occur at constant temperature intervals, providing passive thermal regulation without active heating or cooling systems.
2Adaptability or versatility
If additive manufacturing is performed in space environment, then custom service articles can be fabricated on-orbit, but contamination control becomes difficult due to volatile organic compounds (VOCs)
Solution Approach 1:
The contamination control arrangement extracts and removes VOCs from the additive manufacturing environment using cold plates positioned within the chamber. The cold plates capture volatile organic compounds through condensation, separating them from the vacuum environment and preventing contamination of spacecraft components while allowing the additive manufacturing process to proceed.
Solution Approach 2:
The chamber enclosing the additive manufacturing subsystem maintains a controlled environment that isolates VOCs from sensitive spacecraft components. By creating a contained atmosphere with cold trapping mechanisms, the system effectively inertizes the environment regarding harmful volatile compounds, preventing them from affecting external systems.
3Temperature
If thermal control arrangement with PCM modules is used, then temperature can be maintained within specified ranges, but device complexity increases
Solution Approach 1:
The PCM modules provide self-regulating thermal control through passive phase change mechanisms. The phase change material automatically absorbs excess heat when temperatures rise and releases heat when temperatures fall, without requiring external control systems, sensors, or active intervention. This self-service capability reduces overall system complexity while maintaining effective thermal regulation.
4Object-generated harmful factors
If contamination control arrangement with cold plates is used, then VOCs can be captured, but device complexity increases
Solution Approach 1:
The cold plates convert the harmful effect of VOC outgassing into a beneficial thermal management opportunity. By positioning cold plates to capture volatile organic compounds, the system simultaneously removes contaminants and utilizes the phase change process to maintain thermal conditions. This approach transforms a potential harm (VOC accumulation) into a useful function (contaminant removal and thermal regulation).
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 solution effectively maintains temperature ranges for additive manufacturing tools and workpieces and controls VOC outgassing, ensuring reliable operation and preventing contamination of spacecraft components, thus enabling efficient on-orbit fabrication of custom service articles.
Implementation Method 1
The thermal control arrangement may include a plurality of phase change material (PCM) modules
Implementation Method 2
one or more cold plates disposed in the chamber and configured to capture VOCs
Implementation Method 3
one or more radiative heaters configured to heat the work piece to a temperature above a boiling temperature of the VOCs
Data Source
AI summary
A spacecraft includes an additive manufacturing (A/M) subsystem and one or both of a thermal control arrangement and a contamination control arrangement. The A/M subsystem includes an A/M tool, feedstock and a workpiece and is configured to additively manufacture the workpiece using material from the feedstock. The thermal control arrangement is operable, in an on-orbit space environment characterized by near vacuum pressure and near zero-g force, to maintain temperature of at least one of the A/M tool, the feedstock, and the workpiece within respective specified ranges. The contamination control arrangement is operable, in the on-orbit space environment, to control outgassing of volatile organic compounds (VOCs).