Algorithms for Large Scale Additive Manufacturing in a Free-Flying Environment

Large scale additive manufacturing (LSAM) refers to the fabrication of structures that exceed the build volume of conventional additive manufacturing setups. This can be used for in-space manufacturing (ISM), facilitating the production of large functional structures in space which cannot fit within the payload fairing of a launcher system. In this paper, a new approach for a continuous fabrication process of structural elements is presented, combining the reach of a free-flying satellite and a robotic arm, utilizing a fused filament fabrication (FFF) 3D-printing setup. A motion planning algorithm was developed which calculates energy-efficient movement trajectories based on a truss design input combined with the movement constraints of the satellite and robotic arm. Using this printing paradigm, a long support-free truss was manufactured. This approach was further elevated by extending the truss structure along the second planar axis, thus facilitating the manufacture of structures larger than generally possible through a layer-by-layer approach. Subsequently, combining the segmented and continuous printing approach, a planar truss structure was produced.