How Computational Fluid Dynamics Can Support Manufacturing in Space

Additive manufacturing has been proposed as a solution to the needs of explorers to have readily available means for manufacturing parts in space. Many of the challenges facing additive manufacturing researchers here on earth are exasperated or dramatically changed in space due to the difference in environmental conditions, gravitational forces in particular. Fluids are especially affected by these changes, where the lack of gravity can improve some of the manufacturing constraints such as printing on overhangs, while also creating challenges such as controlling the molten pool characteristics and thermal gradients. In the process of printing metals and polymers to make parts, control of fluid flow, heat transfer, and solidification are of utmost importance. This presentation will discuss some of the solutions available to the research community for modeling processes under different gravitational conditions, and how computational fluid dynamics coupled with analytical and empirical models can address printing challenges. Additionally, specific case studies looking at polymer extrusion and laser-based manufacturing and welding in low to no gravity will be presented.