Turn-Key Use of an Onboard 3D Printer for ISS Operations

Current 3D printing capabilities onboard the International Space Station (ISS) are classified as experimental payloads. As payloads the products of these printers are returned to the ground for testing and analysis. However, it has long been thought that 3D printing must one day become a tool of space operations much like the electrical diagnostic equipment, and the soldering iron. This paper explores a case study in the use of one of the payload 3D printers to manufacture a device to be used by the crew as part of nominal ISS Operations. The nature of this attempt represented a collaboration between the ISS payload community and the systems operations community to capitalize on the strengths of both to accomplish a step in what may one day become a common and cost-savings capability in spaceflight operations. The path from concept development through onboard printing and crew inspection will be described. The lessons learned from this process are reviewed as constructive feedback on how existing processes can be expanded to enable this capability in the future. This experience will be carried forward into the development of a new process which will open the door for future use of 3D printing onboard the ISS.