Small Business Innovation Research/Small Business Tech Transfer
The Vulcan Advanced Hybrid Manufacturing System
Project Description
Made In Space is developing the The Vulcan Advanced Hybrid Manufacturing System (VULCAN) to address NASA�s requirement to produce high-strength, high-precision components on-orbit with comparable quality to commercially-available, terrestrial machined parts. Such capability enables the in-situ manufacturing of critical parts for human spaceflight and without dependence on terrestrial resupply. Made In Space integrates flight-proven microgravity process controls and payload support systems, such as environmental and master controls, with a modular manufacturing & tool system that generates a near net shape for surface finishing or other industrial processing into the final product. One of the key innovations of Made In Space�s VULCAN is the ability to produce finished metal parts with one device, eliminating the need for separate additive manufacturing and subtractive machining facilities. The wire feed architecture of both the thermoplastic extruder and metal manufacturing head allows the hardware to be interchangeable and supported on the same gantry without requiring modification of any of the components. The two manufacturing heads follow the SBM-Spec interface standards for �plug-and-play� operation. Thus, the manufacturing heads can be exchanged easily by crewmembers with no formal manufacturing training. Using this capability, the VULCAN device produces both non-metallic and metallic replacement parts with a minimum of crew interaction. VULCAN is scalable and supports the open SBM-Spec architecture for the thermoplastic and metal manufacturing heads, resulting in a manufacturing methodology that uses multiple materials and can be upgraded over time.
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Anticipated Benefits
The VULCAN technology is primarily intended for sustaining human spaceflight operations, first on the ISS and, later, on long-duration missions to the Moon, Mars, or other destinations in the Solar System. Made In Space has built industry alliances with such companies as Boeing, Lockheed Martin, Orbital ATK, Sierra Nevada Corporation, and Bigelow Aerospace to evaluate the optimal concept of operations for in-space manufacturing as an enabling technology for the NextSTEP Cislunar Habitat. Made In Space is also working with UTC Aerospace Systems and Paragon to develop ECLSS design principles for repair and replenishment by in-space manufacturing. Robotic expeditionary missions can also employ the VULCAN technology for autonomous repairs while building the infrastructure preceding human habitation. Local robots may retrieve and install VULCAN-generated parts automatically or via teleoperation. Such capability may be necessary to ensure continuity of operations without direct human intervention and enable human crews to focus on mission objectives.
The Department of Defense has a demonstrated need for advanced manufacturing capabilities in locations and on forward-deployed platforms without regular logistical support or available resources for traditional fabrication and finishing technologies. Perhaps the foremost example is the US Navy submarine fleet. While aircraft carriers are commonly referred to as �cities at sea� because of their size and on-board industrial capacity, the nation�s attack and ballistic missile submarines deploy for months at a time and must function as entirely self-contained units with no physical connection to the outside world. Submarines on patrol duty may only surface during departure from base and upon return. A tactical version of the VULCAN device gives the DoD a modular, common manufacturing system deployable on mobile platforms, such as submarines, destroyers, transport aircraft, and trucks, and in fixed locations with limited external support, such as Forward Operating Bases and advance airfields.Incumbent 3D printing companies generate revenue from four primary sources: new device sales; feedstock sales; on demand printing; and maintenance services. Made In Space plans to adopt a similar revenue model when developing VULCAN units for commercial use. VULCAN units will be developed and sold to the merchant vessel market. Due to its size and importance, Made In Space will initially target the oil tanker vertical. More »
The Department of Defense has a demonstrated need for advanced manufacturing capabilities in locations and on forward-deployed platforms without regular logistical support or available resources for traditional fabrication and finishing technologies. Perhaps the foremost example is the US Navy submarine fleet. While aircraft carriers are commonly referred to as �cities at sea� because of their size and on-board industrial capacity, the nation�s attack and ballistic missile submarines deploy for months at a time and must function as entirely self-contained units with no physical connection to the outside world. Submarines on patrol duty may only surface during departure from base and upon return. A tactical version of the VULCAN device gives the DoD a modular, common manufacturing system deployable on mobile platforms, such as submarines, destroyers, transport aircraft, and trucks, and in fixed locations with limited external support, such as Forward Operating Bases and advance airfields.Incumbent 3D printing companies generate revenue from four primary sources: new device sales; feedstock sales; on demand printing; and maintenance services. Made In Space plans to adopt a similar revenue model when developing VULCAN units for commercial use. VULCAN units will be developed and sold to the merchant vessel market. Due to its size and importance, Made In Space will initially target the oil tanker vertical. More »
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Primary U.S. Work Locations and Key Partners
| Organizations Performing Work | Role | Type | Location |
|---|---|---|---|
| Made in Space, Inc. | Lead Organization | Industry | JACKSONVILLE, Florida |
Marshall Space Flight Center
(MSFC)
|
Supporting Organization | NASA Center | Huntsville, Alabama |
Primary U.S. Work Locations
-
Alabama
-
Florida
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