LEO Manufacturing of 3D Printed Covetic Nanomaterials for Advanced Electronics

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 NASAs mission, will be done by designing and building a direct print module and method can be incorporated into nScrypts multi-module platform, for subsequent demonstration in a parabolic loop zero-gravity flight test. (Note: the nScrypt multi-module system is the same that NASAs On-Demand Manufacturing of Electronics group is installing on the International Space Station in FY2024). A successful demonstration of the direct print method and modules 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. The innovation is an on-demand direct print technology that uses the unique advantages of manufacturing in LEO to produce value-added next generation materials. Covetics (nanocarbon-infused metals) are difficult to produce on Earth due to gravity effects, but have in-space and terrestrial commercial potential with enhanced properties such as high thermal and electrical conductivity and mechanical strength. Conventional covetics are made by a molten stir process with highly variable carbon-metal distribution and inconsistent properties. Phase I demonstrated an electrocodeposition module / method to direct print covetic materials in a horizontal or vertical orientation, and 50% lower electrical resistivity than pure Cu. Transitioning this direct print technology to an in-space environment, without limitations imposed by gravity, will result in greater property enhancements, create high value-added materials and establish a commercial market for LEO manufacturing. This technology can be integrated into space approved hardware, to accelerate transition and commercialization of LEO space. Phase II objectives: Design and build the direct print module and develop the method that can manufacture covetic materials on-demand in an LEO environment, Demonstrate enhanced material properties of direct print ‘covetic’ materials, Demonstrate the capabilities of the direct print module and method in a zero-gravity flight test Align the technology with NASA and commercial space needs, Establish commercial viability by outreach to companies interested in covetic material properties, Identify a pathway to system scale and implementation on commercial space platforms. Integration into NASA’s mission will be accelerated by incorporating the direct print module and method into nScrypt’s multi-module platform, which will be installed on the ISS in FY24 by NASA’s On-Demand Manufacturing Electronics. A successful demonstration of the performance capabilities of the direct print module and method in a parabolic loop 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. As the market value is validated and method is demonstrated on ISS, we will work with commercial space companies (Axiom Space) to transition the technology. Phase II Deliverables: As-built direct print module, nStructorTM with nStudioTM script to operate direct print module, NASA required reports
Benefits: 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. 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%.