Current In-Space Manufacturing (ISM) relies heavily on terrestrial adaptations like Fused Filament Fabrication (FFF) or Direct Energy Deposition (DED). These methods, however, still use gravity-referenced build plates, layer-by-layer stacking, and support structures. Notably, International Space Station (ISS) 3D printing practices forbid support structures altogether, restricting it to a fraction of its capabilities [1]. A true zero-gravity method could enable contactless, omnidirectional fabrication unconstrained by a single build direction.
To bridge the gap between experimental research and commercial viability, we propose a paradigm shift: Acoustically Levitated Droplet Deposition. By utilising acoustic levitators, a technology consisting of an array of off-the-shelf ultrasonic transducers to create acoustic fields, we can potentially achieve high-precision, non-contact droplet material transport and shaping. This technology leverages the microgravity environment rather than fighting it, allowing for container-less processing and complex 3D geometries controlled entirely by acoustic arrays.
This is a first, proof-of-concept (PoC) assignment. As such, the goal of this thesis is to develop a PoC mechatronic system concept capable of 3D positioning and deposition of material using acoustic levitator technology. The assignment will be focused on developing and adapting an acoustic hardware setup (for instance, [2], [3], [4]), positioning the technology for contactless 3D printing.