Exploring Low-Cost Manufacturing and Design for Space by Material Extrusion of PA6-CF

This paper investigates additive manufacturing (AM) via material extrusion (MEX) with high-performance polymers (HPP) as a prototyping and final application tool for aerospace and, specifically, space applications. AM of HPP offers low-cost, lightweight solutions for low-load, zero-g applications, rapidly enabling advanced geometries without additional expense. This paper explores new materials and design solutions for space by: 1) Investigate manufacturing time and cost with identical CubeSat structures fabricated from aluminum, Nylon with carbon fiber (PA6-CF), and PEEK with carbon fiber (PEEK-CF) with a comparative case study. 2) Explore new design solutions for space enabled by high-performance, low-cost materials manufactured by MEX. This case study design was modified with generative design and design for AM (DfAM) and numerically simulated to assess random vibration response improvements and the impact of varying CF content. 3) Evaluate PA6-CF strict space requirements capabilities by outgassing and evaluating how PA6-CF exhibits enhanced mechanical properties, acceptable total mass loss post-outgassing in thermal-vacuum conditions, and post-machining surfaces have the required surface roughness. AM of HPP integrated with DfAM has the potential to satisfy stringent aerospace requirements. This research shows that PA6-CF can accelerate design cycles, reduce costs, and enable advanced design solutions for satellites and other space systems, highlighting its potential as a space polymer. These findings contribute to the broader discussion on how low-cost materials and advanced manufacturing techniques can revolutionize space mission design and development.