Fused Filament Fabrication of Polyethylene/Graphene Composites for In-Space Manufacturing

Area of Science:

• Materials Science
• Aerospace Engineering
• Additive Manufacturing

Background:

• Graphene composites offer desirable properties like conductivity and radiation shielding for space applications.
• Three-dimensional (3D) printing enables customized component manufacturing for unique space mission demands.
• Developing robust 3D printing processes for space-suitable composites is crucial.

Purpose of the Study:

• To develop and optimize 3D-printed medium-density polyethylene (MDPE) composites reinforced with exfoliated graphene nanoplatelets (xGnP) for space applications.
• To address challenges in fused filament fabrication (FFF) of MDPE/xGnP materials, focusing on filament extrusion and printability.
• To evaluate the material properties and space environmental compatibility of the 3D-printed composites.

Main Methods:

• Optimized filament extrusion and fused filament fabrication (FFF) parameters for MDPE/xGnP composites.
• Differential scanning calorimetry (DSC) to analyze melting and crystallization behavior.
• Electrical and tensile testing, alongside outgassing tests under AM0 solar spectrum exposure.

Main Results:

• Successfully optimized the FFF process for MDPE/xGnP filaments, overcoming challenges like warping and poor adhesion.
• Characterized the thermal and mechanical properties of the 3D-printed composites.
• Demonstrated the space environmental suitability through outgassing tests.

Conclusions:

• The FFF process is capable of efficiently manufacturing MDPE/xGnP composite components.
• Optimized parameters provide a pathway for potential in-space fabrication of these advanced materials.
• The developed composites show promise for multifunctional applications in space missions.