Experimental Investigation of Effect of Gravity on Properties of Parts Fabricated by Fused Deposition Modeling Additive Manufacturing

Additive manufacturing in space has the potential to revolutionize space exploration by enabling the in-situ production of parts. Although fused deposition modeling (FDM) additive manufacturing has been demonstrated in microgravity, its impact on the properties of FDM printed components remains unclear. This thesis attempts to reveal how microgravity affects the mechanical and material properties of parts printed by FDM with microgravity conditions simulated by varying raster and print orientations relative to gravity in the printing process.

The experimental study examines the tensile, compressive, and dimensional properties of fabricated specimens, noting a general decline in tensile strength with increased gravity level at interfacial layers, except for full-gravity specimens that showed a different failure mechanism. Compressive strength and dimensions also decreased with higher gravity. Micro-CT imaging revealed voids, air gaps, and poor interlayer bonding in specimens at low gravity. These findings enhance the understanding of how gravity conditions impact FDM additive manufacturing.