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<p>This study investigates the manufacturing of carbon-fiber-reinforced composite structures performed during the flight of a suborbital rocket. The authors adapted the Direct Robotic Extrusion of Photopolymers process to allow the manufacturing of more complex and carbon-fiber-reinforced structures. A dedicated degassing procedure was developed to effectively limit void formation caused by vacuum conditions: For circular specimens, no statistically significant difference in void volume fraction was observed between ambient pressure (2.2%) and vacuum conditions (2.1%), demonstrating the effectiveness of the implemented degassing approach. A thermogravimetric analysis showed a mass loss of the carbon-fiber filament of 4.4%, supporting the conclusion that its outgassing was responsible for void formation. Under reduced gravity, the void volume fraction increased to 16.5%. Furthermore, adhesion forces dominated the extrusion process in the absence of a gravitational vector, leading to incomplete extrusion of two of the four structures. These results demonstrate that reduced gravity and reduced atmospheric pressure constitute distinct challenges for viscous liquid-based in-space manufacturing processes, and that ground-based vacuum tests alone are insufficient to qualify such processes for spaceflight. A systematic review identified zero eligible studies investigating the manufacturing of carbon-fiber-reinforced structures under simultaneous reduced gravity and reduced atmospheric pressure conditions, indicating a significant research gap.</p>

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Effects of reduced gravity and reduced atmospheric pressure on in-space manufacturing of carbon-fiber-reinforced structures

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年8月4日

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  • Raphael Strecker,
  • Tizian Rieger,
  • Alexander Tabelander,
  • Victor Cudmani,
  • Ulrich Huber,
  • Dennis Klingenberg,
  • Gabriel Wildt,
  • Eric Hennig,
  • Julian Pfender,
  • Johannes Degenfeld-Schonburg,
  • Lukas Rauch

摘要

This study investigates the manufacturing of carbon-fiber-reinforced composite structures performed during the flight of a suborbital rocket. The authors adapted the Direct Robotic Extrusion of Photopolymers process to allow the manufacturing of more complex and carbon-fiber-reinforced structures. A dedicated degassing procedure was developed to effectively limit void formation caused by vacuum conditions: For circular specimens, no statistically significant difference in void volume fraction was observed between ambient pressure (2.2%) and vacuum conditions (2.1%), demonstrating the effectiveness of the implemented degassing approach. A thermogravimetric analysis showed a mass loss of the carbon-fiber filament of 4.4%, supporting the conclusion that its outgassing was responsible for void formation. Under reduced gravity, the void volume fraction increased to 16.5%. Furthermore, adhesion forces dominated the extrusion process in the absence of a gravitational vector, leading to incomplete extrusion of two of the four structures. These results demonstrate that reduced gravity and reduced atmospheric pressure constitute distinct challenges for viscous liquid-based in-space manufacturing processes, and that ground-based vacuum tests alone are insufficient to qualify such processes for spaceflight. A systematic review identified zero eligible studies investigating the manufacturing of carbon-fiber-reinforced structures under simultaneous reduced gravity and reduced atmospheric pressure conditions, indicating a significant research gap.