The aerospace sector stands out as one of the main beneficiaries of the benefits of additive manufacturing. Thanks to 3D printing, complex and lightweight components can now be designed and produced with unprecedented speed and efficiency, revolutionizing not only aerospace but also various other sectors. A revolutionary moment in space exploration and additive manufacturing occurred when a team from the FAMU-FSU College of Engineering, a collaborative institution between Florida A&M University and Florida State University, successfully developed 3D printed sensors for NASA. This achievement represents a notable advancement in the use of 3D printing technology to manufacture high-performance components, promising remarkable advances in both space exploration and manufacturing capabilities.
The research team, comprising engineering students and experienced engineers, was led by Professor Subramanian Ramakrishnan from the Department of Chemical and Biomedical Engineering. Thanks to the expertise of the multidisciplinary team and the decision to use innovative technologies such as additive technologies, they were able to produce cutting-edge sensors that mechanically outperform conventional sensors used in the aerospace industry. This breakthrough is the result of NASA’s Additive Manufacturing of Electronics for NASA Applications project, on which work will continue for another year. The universities received $300,000 for research and development of the sensors, which will be supported by NASA engineers.
Professor Subramanian Ramakrishnan, project manager (Photo credit: FAMU-FSU College of Engineering).
Sensors play a crucial role in aerospace initiatives, translating physical phenomena into electrical signals for computer processing. This critical function allows engineers to understand how space systems behave in the face of the rigors of space. Among the multitude of types of sensors with specific functions, strain gauges stand out. These sensors are essential for measuring the deformation of objects, providing valuable information about structural integrity. During aerospace missions, these devices play a vital role by diligently monitoring systems in real time. Their vigilance is essential to avoid any deformation that could compromise the safety and operational efficiency of spacecraft.
3D printing drives aerospace innovation
To produce the strain gauges, which are a flexible, insulating stamping, 3D printing was used in combination with a laser baking method that involves heating the ink to improve its properties without melting it. The sensors were printed with silver ink and with the help of a printer from the manufacturer nScrypt, which is ideal for printing on curved surfaces. The combination of the two techniques gave a product with optimal mechanical and electrical properties. The sensors are more precise and have shown better performance when measuring the deformation of objects. About the next step in sensor development, Professor Ramakrishnan said: “We are also experimenting with new ink formations and process parameters that will lead to new design rules and better methods for additive manufacturing rapid development of new generation sensors at NASA. »
The project shows how space technology is redefining its limits. The two-year grant, awarded through NASA’s Science Mission Directorate (SMD) Bridge Program, aims to promote diversity, equity, inclusion and accessibility in the workforce of NASA and the scientific and technical community of the United States. “Students will spend the fall and spring semesters at the university and work with NASA scientists at one of the centers,” Ramakrishnan said. “They will have access to mentoring and networking opportunities throughout the year. Students will learn while building a product to launch future rocket missions. »
(Photo credits: Florida State University)
The program focuses on mentoring students and extending their hands-on training to shape tomorrow’s NASA scientists, as well as easing students’ transition to graduate school or STEM careers. Beth Paquette, an aerospace engineer at NASA’s Goddard Space Flight Center in Greenbelt, Maryland, and Curtis Hill, a principal investigator at NASA’s Marshall Space Flight Center in Huntsville, Alabama, also collaborated on the project and are among the experts who will work with the students.
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*Cover photo credits: FAMU-FSU College of Engineering
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