Advancing Additive Manufacturing For Extreme Environments Through Simulated Microgravity Printing

Additive Manufacturing (AM) holds significant potential for space exploration by enabling on-demand fabrication of components, reducing payload costs, and enhancing mission adaptability. However, microgravity introduces challenges in thermal regulation, material deposition, and structural integrity. This research explores the feasibility of submerged AM using neutral buoyancy in silicone oil to simulate microgravity conditions on Earth. A 3D printer was modified for submerged operation, with samples printed under three conditions: no oil (ambient air), submerged in oil, and simulated microgravity at varying temperatures. Mechanical tests, fracture surface analysis, and density measurements were performed to evaluate tensile strength, surface adhesion, and dimensional stability. Results indicate that air-printed samples exhibited superior layer adhesion and elongation, while submerged prints displayed quasi-brittle fracture due to rapid cooling in oil. Prints at 5 mm/s in oil showed improved bonding over 20 mm/s prints, attributed to extended heat exposure during deposition. Thermal analysis identified 100°C as the optimal oil temperature for submerged printing, minimizing warping and enhancing structural stability. This study demonstrates the potential of neutral buoyancy as an effective simulation method for space-based AM, revealing critical parameters for optimizing submerged printing. These findings contribute to the development of sustainable, in-situ manufacturing solutions for space missions.