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The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including for manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions independently of the gravitational environment and with no restriction on feedstock powder flowability. Based on a specific sequence of boundary loads applied to the granular packing, powder is transported to the printing zone, homogenized and put under compression to increase the density of the final part. The powder deposition process is validated by simulations that show the homogeneity and density of deposition to be insensitive to gravity and cohesion forces within the DEM model. We further provide an experimental proof of concept of the process by successfully 3D printing parts on-ground and in weightlessness, on parabolic flight. Powders exhibiting high and low flowability are used as model feedstock material to demonstrate the versatility of the process, opening the way for additive manufacturing of recycled material.
A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing
Plastic scintillator detectors are widely used in particle physics thanks to the very good particle identification, tracking capabilities and time resolution. However, new experimental challenges and the need for enhanced performance require the cons
Wire-feed laser additive manufacturing (WLAM) is gaining wide interest due to its high level of automation, high deposition rates, and good quality of printed parts. In-process monitoring and feedback controls that would reduce the uncertainty in the
Numerical simulations are used in this work to investigate aspects of microstructure and microsegregation during rapid solidification of a Ni-based superalloy in a laser powder bed fusion additive manufacturing process. Thermal modeling by finite ele
To control part quality, it is critical to analyze pore generation mechanisms, laying theoretical foundation for future porosity control. Current porosity analysis models use machine setting parameters, such as laser angle and part pose. However, the