Research on the Formation Mechanism of Low Power Metal-Fuse Additive Manufacturing In-Space

Wire-feed direct metal deposition (DMD) additive manufacturing (AM) has demonstrated strong adaptability in microgravity environments, making it a preferred solution for in-situ space fabrication. However, space-oriented metal AM faces significant constraints due to the high cost of Earth-to-space transport and must meet demanding requirements for miniaturization and low power consumption. This study proposes a metal fusion AM technique utilizing a Joule–laser hybrid heat source and investigates its forming mechanism and processing behavior. The influence of various process parameters on formation quality is thoroughly analyzed, and optimal conditions are identified. Experimental results indicate that, using a 0.3 mm diameter stainless steel wire, the hybrid heat source enables high-quality deposition at a low laser power of 50 W—reducing total power consumption by 36% compared to single-laser wire melting. This study provides both theoretical and experimental support for developing low-power metal wire AM processes, contributing to the miniaturization and lightweighting of spaceborne AM equipment.