Relativity Space’s Quest To 3D Print Entire Rockets

October 30, 2018 by Tom Nardi 27 Comments

While the jury is still out on 3D printing for the consumer market, there’s little question that it’s becoming a major part of next generation manufacturing. While we often think of 3D printing as a way to create highly customized one-off objects, that’s a conclusion largely based on how we as individuals use the technology. When you’re building something as complex as a rocket engine, the true advantage of 3D printing is the ability to not only rapidly iterate your design, but to produce objects with internal geometries that would be difficult if not impossible to create with traditional tooling.

So it’s no wonder that key “New Space” players like SpaceX and Blue Origin make use of 3D printed components in their vehicles. Even NASA has been dipping their proverbial toe in the additive manufacturing waters, testing printed parts for the Space Launch System’s RS-25 engine. It would be safe to say that from this point forward, most of our exploits off of the planet’s surface will involve additive manufacturing in some capacity.

But one of the latest players to enter the commercial spaceflight industry, Relativity Space, thinks we can take the concept even farther. Not content to just 3D print rocket components, founders Tim Ellis and Jordan Noone believe the entire rocket can be printed. Minus electrical components and a few parts which operate in extremely high stress environments such as inside the pump turbines, Relativity Space claims up to 95% of their rocket could eventually be produced with additive manufacturing.

If you think 3D printing a rocket sounds implausible, you aren’t alone. It’s a bold claim, so far the aerospace industry has only managed to print relatively small rocket engines; so printing an entire vehicle would be an exceptionally large leap in capability. But with talent pulled from major aerospace players, a recently inked deal for a 20 year lease on a test site at NASA’s Stennis Space Center, and access to the world’s largest metal 3D printer, they’re certainly going all in on the idea. Let’s take a look at what they’ve got planned.

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The Science Of Landing On An Asteroid

October 16, 2018 by Dan Maloney 17 Comments

Exploiting the resources of the rock-strewn expanse of space between Mars and the outer planets has been the stuff of science fiction for ages. There’s gold in them ‘thar space rocks, or diamonds, or platinum, or something that makes them attractive targets for capitalists and scientists alike. But before actually extracting the riches of the asteroid belt, stuck here as we are at the bottom of a very deep gravity well that’s very expensive to climb out of, we have to answer a few questions. Like, how does one rendezvous with an asteroid? What’s involved with maneuvering near a comparatively tiny celestial body? And most importantly, how exactly does one land on an asteroid and do any useful work?

Back in June, a spacecraft launched by the Japanese Aerospace Exploration Agency (JAXA) finally caught up to an asteroid named Ryugu after having chased it for the better part of four years. The Hayabusa2 was equipped to answer all those questions and more, and as it settled in close to the asteroid with a small fleet of robotic rovers on board, it was about to make history. Here’s how they managed to not only land on an asteroid, but how the rovers move around on the surface, and how they’ll return samples of the asteroid to Earth for study.

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Friday Hack Chat: Is There Life On Mars?

October 3, 2018 by Brian Benchoff 14 Comments

Mars ain’t the kind of place to raise a kid. In fact, it’s cold as hell. There’s no one there to raise them if you did, or is there? Is there life on Mars? That’s the question NASA has been trying to answer for the last forty years, and with the new Mars rover, we might get closer to an answer. For this week’s Hack Chat, we’re going to be talking with the people responsible for some interesting instruments flying on the Mars 2020 rover.

Our guest for this week’s Hack Chat will be [Matteo Borri], an Italian engineer who’s been living in the US for the better part of a decade now. He’s had various projects ranging from robotics — including a BattleBot — AI, and aerospace. [Matteo] is also one of the engineers behind the Vampire Charger, a winner in the Power Harvesting Module Challenge in this year’s Hackaday Prize.

Right now, [Matteo] is working on an interesting project that’s going to fly on the next Mars rover. He’s developed a chlorophyll spectroscope for NASA and the Mars Society. This week, [Matteo] is going to share the details of how this device works and how it was developed.

During this Hack Chat, we’re going to be discussing various technology that’s going into the search for life on Mars and elsewhere in the galaxy such as:

Chlorophyll detection
Mars Rovers
Various other hardware hacks

You are, of course, encouraged to add your own questions to the discussion. You can do that by leaving a comment on the Hacking with Fire event page and we’ll put that in the queue for the Hack Chat discussion.

Our Hack Chats are live community events on the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Friday, October 5th, at noon, Pacific time. We have some amazing time conversion technology.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io.

You don’t have to wait until Friday; join whenever you want and you can see what the community is talking about.

3D Printing In Metal: The Laser And Metal Powder Printers We Saw At IMTS

September 17, 2018 by Mike Szczys 24 Comments

Last week I went to the International Manufacturing Technology Show (IMTS) and it was incredible. This is a toy store for machinists and showcases the best of industrial automation. But one of the coolest trends I found at the show are all the techniques used to 3D print in metal. The best part is that many of the huge machines on display are actually running!

It’s probably better to refer to this as additive manufacturing, because the actual methods can be significantly different from your 3D printer. Below you’ll find examples of three different approaches to this process. I had a great interview with a company doing actual 3D printing in metal using a nozzle-based delivery often called cladding. There’s a demo video of powder layer printing using lasers. And a technique that uses binders as an intermediary step toward the final metal part. Let’s take a look!

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One Small Step For A Space Elevator

September 14, 2018 by Tom Nardi 149 Comments

Space elevators belong to that class of technology that we all want to see become a reality within our lifetimes, but deep-down doubt we’ll ever get to witness firsthand. Like cold fusion, or faster than light travel, we understand the principles that should make these concepts possible, but they’re so far beyond our technical understanding that they might as well be fantasy.

Except, maybe not. When Japan Aerospace Exploration Agency (JAXA) launches their seventh Kounotori H-II Transfer Vehicle towards the International Space Station, riding along with the experiments and supplies for the astronauts, will be a very special pair of CubeSats. They make up the world’s first practical test of space elevator technology, and with any luck, will be one of many small steps that precedes the giant leap which access to space at a fraction of the cost will be.

Of course, they won’t be testing a fully functional space elevator; even the most aggressive of timelines put us a few decades out from that. This will simply be a small scale test of some of the concepts that are central to building a space elevator, as we need to learn to crawl before we can walk. But even if we aren’t around to see the first practical space elevator make it to the top, at least we can say we were there on the ground floor.

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Six Wheels (En)rolling: Mars Rovers Going To School

August 3, 2018 by Roger Cheng 7 Comments

Few things build excitement like going to space. It captures the imagination of young and old alike. Teachers love to leverage the latest space news to raise interest in their students, and space agencies are happy to provide resources to help. The latest in a long line of educator resources released by NASA is an Open Source Rover designed at Jet Propulsion Laboratory.

JPL is the birthplace of Mars rovers Sojourner, Spirit, Opportunity, and Curiosity. They’ve been researching robotic explorers for decades, so it’s no surprise they have many rovers running around. The open source rover’s direct predecessor is ROV-E, whose construction process closely followed procedures for engineering space flight hardware. This gave a team of early career engineers experience in the process before they built equipment destined for space. In addition to learning various roles within a team, they also learned to work with JPL resources like submitting orders to the machine shop to make ROV-E parts.

ROV-E

ROV-E Team

Once completed, ROV-E became a fixture at JPL public events and occasionally visits nearby schools as part of educational outreach programs. And inevitably a teacher at the school would ask “The kids love ROV-E! Can we make our own rover?” Since most schools don’t have 5-axis CNC machines or autoclaves to cure carbon fiber composites, the answer used to be “No.”

Until now.

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Kepler Planet Hunter Nears End Of Epic Journey

July 31, 2018 by Tom Nardi 50 Comments

The Kepler spacecraft is in the final moments of its life. NASA isn’t quite sure when they’ll say their last goodbye to the space telescope which has confirmed the existence of thousands of exoplanets since its launch in 2009, but most estimates give it a few months at best. The prognosis is simple: she’s out of gas. Without propellant for its thrusters, Kepler can’t orient itself, and that means it can’t point its antenna to Earth to communicate.

Now far as spacecraft failures go, propellant depletion isn’t exactly unexpected. After all, it can’t pull into the nearest service station to top off the tanks. What makes the fact that Kepler will finally have to cease operations for such a mundane reason interesting is that the roughly $600 million dollar space telescope has already “died” once before. Back in 2013, NASA announced Kepler was irreparably damaged following a series of critical system failures that had started the previous year.

But thanks to what was perhaps some of the best last-ditch effort hacking NASA has done since they brought the crew of Apollo 13 home safely, a novel way of getting the spacecraft back under control was implemented. While it was never quite the same, Kepler was able to continue on with modified mission parameters and to date has delivered so much raw data that scientists will be analyzing it for years to come. Not bad for a dead bird.

Before Kepler goes dark for good, let’s take a look at how NASA managed to resurrect this planet hunting space telescope and greatly expand our knowledge of the planets in our galaxy.

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