How much does it cost per pound to launch something into space? (We are trying to figure out how much our product would cost to be launched)
The cost of delivering hardware to orbit varies. A satellite for example, which I recognize is not what you are considering, costs anywhere from $10,000. per pound to $30,000 or more. per pound to launch. Dedicated launch versus shared launches and reliability are key factors in the variability of cost. Small payloads to ISS and or "student" payload launch opportunities cost less.
NanoRacks is another way to get products for testing to ISS and they start at about $25,000. for delivery. Another way to get a Product to orbit is to pursue Research Grants for NASA, NOAA or the Dept of Energy. the NanoRacks website will tell you more.
Our product is a 3-D printing Module that would be connected to the ISS. Any suggestions on the material this module should be made out of on its outside?
Material considerations - The first is assuming that the Printer would be inside of ISS, the environment is rather benign, as it is pressurized and has thermal control, so that gives you latitude in material selection. Materials need to be non-flammable, non-toxic and that do not outgas condensable materials over time. Furthermore they cannot have the potential of any other hazards such as shattering, or emit particles like powder, so I am not sure how you could use a powder based printer. Another considerations is if you are using microelectronics, radiation can cause what is referred to as "single event upsets" that change memory states or processor functions. This may not be a problem you will have depending on the design of the printer electronics, but you may want to understand if it is.
In space, if we were to have a powdered 3-D printer, would that work, or would the powder go all over because of no gravity?
As I noted above I don't see how it could work in Zero G.
How much does it cost NASA or whomever, to keep up different modules on the space station?
The overall operating costs for Space Station is over $1.5 Billion per year.
What types of items have not survived liftoff because of the forces of getting into space?
Given that either the either the design or the protective packaging for things going to orbit are designed to withstand the launch environment this is not typically a problem.
What materials do best in space?
It depends on the space environment to which it is exposed and the application. For example as described above the, if used inside a controlled environment like on-board the ISS, typically the materials need only to be non-flammable, non-toxic and that they do not require gravity to maintain their integrity.
For materials used on satellites or payloads that mount on the ISS external truss for example, you need to consider how they can be stressed to the changing extremes in temperature as they are exposed to the sun and then cold space each orbit.Thermal controls are typically required to maintain Thermal equilibrium such as heaters, insulation and radiators. Materials that have good thermal conductivity for example will equalize quickly and have less internal stress that causes bending for example. Since there no atmosphere the next thing to consider is does the material out-gas and deteriorate over time. A second is will the application be in low earth orbit where there is atomic oxygen that in effect wears down and changes the thermal properties of the material over time.
1. Since additive manufacturing is based on layering different types of materials, how would the lack of gravity in space affect this process? Would it be necessary to create an artificial source of gravity for the machine?
1) The lack of gravity could have different effects on the layering of materials. It depends on the system that is being used (powder-based, resin-based, film-based, etc.). The machine itself would likely need to be operated in a gravity controlled space. Many of the systems require specific calibration and the ability to lay down material without concern of it "floating away" before it is cured. I don't think it would be good to have thousands of tiny metal or nylon particles floating around a space craft. The machines all operate in very specific patterns and the lack of gravity could have a significant impact on its ability to perform. The FDM technology created by Stratasys is the one system that may be able to operate without gravity since the material begins as a solid film that is the melted and cured instantly in a closed chamber. Without testing in a gravity-less atmosphere it is tough to know for sure.
2. Is there a specific method for additive manufacturing that would be better suited for use in space? (SLS vs FDM etc...)
2) Now this is a very tough question to answer because the "best" technology largely depends on the specific application. One of the reasons we offer so many different technologies is because every project is unique and has different requirements (heat, strength, tolerances, etc.). Without knowing how the additive technology is planned on being used in space I am kind of shooting in the dark. Build platform size varies in each technology and plays a significant role in determining which system would be best. Would the space application be looking for large parts or for small parts to build? There is also the concern of having to store the raw materials and clean the parts. Some additive technologies require some post-processing to get the parts to a finished state. To speak vaguely, SLS provides some of the most production ready materials and is already being used in many aerospace applications.
I have attached a presentation we have used recently that will provide some of the information:
Slide 4-Marketplaces we focus on selling printers to
Slide 10-List of some customers
Slide 13- Types of materials that are used in printers
Slide 27 – Price ranges by the categories of printers we sell (Use ‘combined’ line as we have just completed an acquisition which adds $20,000 to $60,000 printers)
( Becca has access to this PowerPoint if someone wishes to look at it)
As for inside structure, that depends on the printer type. We have 7 different print engines, or printer technologies. Here is a basic description and web links for more info and pictures:
1) Plastic Jet Printing- plastic materials are extruded through 1-3 heads – Botmill™, RapMan™ and 3DTouch™ printers - $1,300-$3,900;