Intricacies of 3D printing with freeze casting in microgravity

• Author / Creator

  Ahmed, Abrar

• The burgeoning demand for advancements in space technology and the relentless pursuit of exploring uncharted celestial frontiers necessitate a comprehensive grasp of the multifaceted aspects underpinning the sustainability of space missions. In this context, additive manufacturing (AM) has emerged as an enticing proposition for inclusion in the tool-kit of every space mission, primarily owing to its capacity to fabricate components on-demand.

  The overarching objective of this doctoral thesis is to engineer a compact laboratory platform, herein referred to as FrizCast\nonTM , dedicated to unraveling the intricate intricacies of various processes integral to conventional additive manufacturing. These processes encompass material deposition, additive layering, solidification, and post-processing procedures. In the austere environment of space, characterized by the absence of gravitational forces, interfacial forces wield significant influence over the outcomes at each stage of the additive manufacturing process.

  The research endeavors in this thesis will scrutinize the three dimensional (3D) printing process, both within terrestrial conditions and within reduced-gravity settings, with a keen focus on elucidating the fundamental principles governing colloidal material delivery, drop-based material accretion, multilayer mass accumulation via colloidal droplet coalescence, and the subsequent solidification processes. Given the prevalence of lower temperatures in space, our investigations have led us to adopt freeze casting as an integral facet of the additive manufacturing process. During material solidification, external body forces will be harnessed to facilitate the manipulation of the final shape of the solidified material. Consequently, the widely employed electromagnetic field will be subjected to a rigorous examination to discern its impact on the aforementioned facets of the additive manufacturing process.

  The ultimate aim of this project is to propose a jet-based 3D printing mechanism, which has the potential of being used in space and to study how surface and body forces affect the 3D printing process on a printer bed. Furthermore, we have also establish a prototypical instrument that could serve as a blueprint for future space missions necessitating recurrent measurements of surface tension, surface energy, as well as 3D printing of metallic and biomaterials. Thus, this research initiative holds the potential to become an invaluable asset for the future of space exploration.

• Subjects / Keywords

  • Microgravity
  • Surface Science
  • 3D printing in space

• Graduation date

  Spring 2024

• Type of Item

  Thesis

• Degree

  Doctor of Philosophy

• DOI

  https://doi.org/10.7939/r3-4yhs-xa38

• License

  This thesis is made available by the University of Alberta Libraries with permission of the copyright owner solely for non-commercial purposes. This thesis, or any portion thereof, may not otherwise be copied or reproduced without the written consent of the copyright owner, except to the extent permitted by Canadian copyright law.