A group of researchers at the University of California, Berkeley, recently completed another successful test of their microgravity 3D printing system, SpaceCAL. This next-gen device could open the door for deep space travel by enabling astronauts to print parts, tools, medicine, and even organs when needed. These capabilities are still a long way away, and this latest test marks another milestone in their journey.
Research on printing in space has increased over the last five years. These units differ from their earthly predecessors because they can’t rely on gravity to assist their layering processes. As such, engineers have had to develop new ways to mold their prints.
CAL
The SpaceCAL project leverages a new method of 3D printing called CAL “computed axial lithography”. This method introduces sensitive polymers that react to light. The photosensitive resin can be shaped using lasers into complex 3D structures. Notably, the CAL 3D printing method was developed in 2017 by Hayden Taylor, the lead researcher on the SpaceCAL project.
The CAL 3D printing method is ideal for low-gravity manufacturing because it doesn’t rely on a layering approach. Instead, the material is included in a chamber before dual lasers are used to mold and stiffen the print. One of the main benefits of the CAL printing method is that it streamlines development and only requires a single unit.
SpaceCAL
The SpaceCAL project applies the research and development that has occurred since 2017 to the printing method. The results are an enclosed, safe, and reliable way to print a massive selection of materials while in orbit or other microgravity scenarios. Notably, SpaceCAL has already completed multiple low-gravity trials. However, this latest one was the first to enter orbit.
Source – Virgin Galactic
SpaceCAL Test
Testing of the SPaceCAL printing system took place aboard the Virgin Galactic VSS Unity on June 8, 2024. Virgin Galactic took the device into suborbital space, which enabled it to conduct a 140-second trial run. The engineers selected four benchys as their prints. Benchys are used to test the accuracy and capabilities of 3D printers.
These test prints range in complexity from simple designs, all the way to complex multi-material structures. For this test, the scientist kept the prints relatively basic. Specifically, they printed four benchys including a small spacecraft and some tugboats. Notably, the benchys were printed using a light-sensitive plastic resin called PEGDA.
Results
The results of the test flight proved successful. SpaceCAL completed the prints in the small window of time allotted. They were accurate to the designs and took as little as 20 seconds for each to complete. According to researchers, the next tests will attempt prolonged printing and more intricate designs.
SpaceCAL Benefits
There are a lot of benefits that the SpaceCAL project could bring to the market. For one, it enables travelers to quickly and accurately print parts in emergencies. The unit offers direct-on-demand printing that can be controlled from the home base, or by astronauts in flight. For deep space travelers, this option eliminates the need to pack thousands of potential spare parts.
Different Materials
The SpaceCAL printing method is extremely flexible. The researchers have already tested their printing method using +60 different materials. These devices can print using silicones, plastics, glass composites, biomaterials, and more. As such, they are ideal for resource-scarce environments such as spaceships where every piece of waste could be recycled into useful prints.
Space travel has to take into account every gram of weight. As such, it’s crucial to create a 3D printing method that can handle printing durable parts and tools, while also supporting tissue and organic materials. The SpaceCAL printer’s versatility could make it the ideal solution for these tasks moving forward. Additionally, as new resins, polymers, and metal composites emerge, these devices can integrate the upgraded material, creating strong and more complex prints in less time.
Single Print
Another benefit that SpaceCAL brings to space travelers is the ability to create using a single print step. Many current 3D printing methods require multiple steps, which adds to the materials, complexity, costs, and weight of the devices. The SpaceCAL printer can create intricate custom-defined 3D geometries in a single print step, improving efficiency and safety.
Faster Prints
The SpaceCal printing method is very fast compared to layering methods. The test results showed that the 3D-printed benchys only took around 20 seconds per print. This speed opens the door for new use cases for these units in the future. Imagine a space traveler quickly printing an energy part, tool, or other needed item without delay. Notably, this approach is much faster than today’s methods and can take hours to complete a single complex print.
Freedom of Design
One of the biggest advantages this research has shown is that microgravity 3D printers can print items that aren’t possible on Earth. These low-gravity environments improve material flow and enable engineers to be more creative in their designs. As such, the future could see orbital additive manufactured products become crucial elements of daily life.
Use Cases for SpaceCAL
There are several immediate use cases for the SpaceCAL printers. Primarily, they are seen as crucial elements of deep space travel. There are even plans to use these devices to help colonize the moon. This latest test validates the team’s research and demonstrates the improved performance the SpaceCAL method provides. In the future, variations of these devices could be used to print everything from parts to homes.
Medical Needs
One of the coolest and most sci-fi aspects of the SpaceCAL project is its ability to print biomaterials. Imagine astronauts printing organs, dental needs, skin grafts, and even new lenses. The researchers see this as the eventual future for their creation. They envision a day when SpaceCAL printers are used to create organs that would be impossible to print on Earth. These organs could be used by astronauts or shipped back to the planet for use by the population.
Researchers
Research for this project included a team of UC Berkeley and Lawrence Livermore National Laboratory (LLNL) students led by Hayden Taylor. Researchers Dillon Balk, Jacob Gottesman, Skyler Chan, Sean Chu, Brian Chung, Ameera Elgonemy, Anthony Moody, Jake Nickel, Dylan Potter, Austin Portinause, Anusri Sreenath, and Audrey Young helped develop and test the SpaceCAL concept as well.
SpaceCAL has support from NASA’s Flight Opportunities program, Berkeley Engineering, and the currently under-construction Berkeley Space Center. Additionally, the project secured a $1.4 million grant for the project, which enabled researchers to improve their device and testing.
Companies that Could Leverage this Study to Improve Revenue
Several manufacturers could integrate SpaceCAL printing technology to provide new or improve existing products. These firms already have strong positioning in their respective markets and the introduction of high speed and efficient SpaceCAL printing methods could greatly improve their offerings.
Organovo Holdings 
Organovo Holdings is a pioneering biomedical 3D printing. The company’s goal is to use 3D printers to mimic human organs and tissues, enabling researchers to study the effects of medications, the environment, and other factors without putting people at risk.
Organovo Holdings is based in San Diego and is a pioneer in the 3D bio-tissue printing field. Its products enable researchers to study diseases, infections, and their potential cures. The ability to print tissue and organic material opens the door for a future where donors aren’t needed and emergency medical procedures can occur faster, saving millions of lives yearly.
Organovo Holdings is a strong addition to your portfolio. The company recently spoke on their research at this year’s Digestive Disease Week (DDW2024). The firm’s positioning as a frontrunner in the market, plus the growing demand for biomedical printed services, positions Organovo Holdings for future success.
Proto Labs 
Proto Labs entered the market in 1999 and is based in Maple Plain, Minnesota. The company specializes in short-run and prototyping prints. It offers various services, including quick-turnaround additive manufacturing and injection molding. The firm’s speedy turnaround and flexibility have helped it secure a dominant position in its market.
Proto Labs has intel spanning across a massive range of industries. Specifically, the company offers consumer products, medical devices, and automotive parts. The manufacturer enables engineers to build in popular software like CAD and then send their prints for fast results. Proto Labs returns prints in days, making it the premier solution for prototyping.
The demand for Proto Labs services has continually increased over the years. The firm currently has a market cap of $857.71M. If Proto Labs could integrate SpaceCAL technologies into its business model, it could offer even faster prototyping to its clientele. It could also reduce printing costs and eliminate the need for many of its current printers.
Future of 3D Printing
The future of 3D printing looks bright. There have been many major developments in the industry in the last few years. Today’s most advanced 3D printers now use low-power lasers and can print multiple materials using a single device. As such, it’s now possible to print working complex and even electrical devices.
Deep Space Research
Deep space research continues to fuel R&D efforts. Recently, 3D-printed hearts were brought into the International Space Station. The goal was to see the effects of space radiation on organs. The research is part of a larger mission that has seen support from Brown and Johns Hopkins University, as well as, NASA.
Easy Interfaces
Large Language Model AI chatbots are another major development that will reshape the 3D printing experience. These interfaces enable people to communicate with computers like humans. Programs like ChatGPT have demonstrated the power of these tools and how they can improve efficiency, expand capabilities, and lower costs.
In the future, 3D printing won’t require a lot of technical skill. Most units will only need text or voice directions to complete complex tasks that they learned gradually over years of data and upgrades to their AI models. When you combine the prospect of SpaceCAL printing technology with advanced AI capabilities, the tech seems to have endless potential.
High Efficiency Printers
Recently, researchers created a new dual laser printing method that reduces cost and waste. This method converted one of the usual femtosecond lasers into a lower-powered unit. The team then introduced a new computational formula that enabled them to determine an optimal tuning between the lasers. The results are similar to the original dual femtosecond lasers.
The new approach used a much cheaper laser alternative, which lowered costs significantly. Additionally, this upgrade can be adapted to fit most current laser 3D printers in use in the manufacturing sector with minimal effort. As such, this upgrade could help to lower 3D printing costs globally and open the door for even more affordable devices soon.
Another Successful Test
This latest round of testing highlights how fast the team progressed in its mission. You can expect to hear more about this project as the engineers seek to print complex devices during space travel. For now, this innovative team’s pioneering efforts into microgravity printing could improve the lives of billions of people one day.
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