Direct ink writing of viscous inks in variable gravity regimes using parabolic flights

Additive manufacturing (AM) has significant utility for off-planet fabrication where dedicated infrastructure is severely limited, weight reduction and in situ resource utilization is desirable, and demands for complex systems are high. Direct ink writing (DIW) is a useful AM technique since it enables the deposition of a broad set of materials and the co-printing of multiple materials simultaneously. This allows for the fabrication of complex functional devices and systems in addition to structural objects. To evaluate this technique for space applications, this study characterized DIW in low gravity environments. Parabolic flights were used to simulate Martian, Lunar, and Micro gravity, and the effects that these 3 gravity regimes have on two critical print performance parameters, drooping and slumping, was evaluated using viscous paste inks deposited with an auger-driven extrusion head. In the drooping case, bridging structures were printed across gaps without support material, and the deformation was monitored. In the slumping case, a wall was printed through sequential layer deposition, and the vertical displacement of each layer under reduced gravity was explored. As expected, we found that a reduction in apparent gravity led to a decrease in the droop of a printed line, and as apparent gravitational acceleration is decreased its impact on the magnitude of drooping becomes less significant. For wall structures printed in simulated Lunar or Martian gravity regimes, the total structure height was found to be similar to that of a structure printed under Earth's gravitational conditions. In contrast, for prints performed in microgravity, it was found that slumping was significantly reduced and structure height was larger. These results provide experimental data to enable the design and optimization of appropriate structures and tool paths for printing objects using DIW for off-planet manufacturing.