SSC24-WP1-37

Preliminary Design of a 3D Printing System for Creating Infinitely Large Structures in

Space
Stephen Timperley, Grant Stec
United States Air Force Academy
Fairchild Drive, USAF Academy, Colorado, 80841
[email protected], [email protected]

Daniel Miller
Department of Astronautics - USAFA
[email protected]

Distribution Statement A. Approved for public release: distribution is unlimited.

ABSTRACT
As interest in the space environment grows, the demand for larger and more capable space systems will follow. A
possible solution to fill this demand is additive manufacturing in the form of 3D printing. This paper showcases a
working preliminary system to 3D print large structures in space from a small satellite. This is achieved by replacing
the normal Z axis control of a conventional CoreXY fused deposition modeling (FDM) 3D printer with a system to
move along an infinitely extendable printed track. Having the ability to print and then move along this track creates
a cycle of printing and movement that can extend the Z axis infinitely. The proposed track system utilizes three
faces of the four-faced track allowing for one face to be used as a connection point for other structures. In
demonstration, a cylindrical tube was printed adjacent to the track to simulate the creation of a space station capsule.
While the CoreXY printer was useful for demonstrating the Z axis control of the track system, a robotic arm with an
attached printer head would best utilize the unique Z mechanism. With future work this robotic arm system could
start printing tracks in all directions that could then be switched to and from allowing for the print volume to be
extended infinitely in all three dimensions. This would provide small satellites the ability to build structures
infinitely beyond their size.

INTRODUCTION was designed to create large apertures but theoretically

Additive manufacturing in space is not a new concept. could be used to print any large structure.15
The ISS has operated a 3D printer for over a decade in
AFIT’s concept features a tube crawling 3D printer that
the micro gravity environment while multiple tests on
extends the tube that it moves along. The concept is also
earth have confirmed the ability to 3D print under
designed to print the tube in branching directions.5
vacuum.2,11,14 All of these tests show a potential for
additive manufacturing in space. The benefit of 3D Redwire Space developed a working prototype printer as
printing objects in space comes down to three things: part of NASA’s On-Orbit, Servicing, Assembly, and
allowing for unique architectures, avoiding the launch Manufacturing 2 (OSAM-2) project. Their design prints
environment, and overcoming volume limitations of the beams for extending solar arrays in space.10
rocket fairing.5 While 3D printing in space is feasible, to
truly capture all benefits, a printer should not be limited Lastly, Mitsubishi Electric Research Lab developed a
by the rocket fairing volume. Most current 3D printers working prototype 3D printer satellite system for
can only produce objects smaller than themselves. producing large communication dishes. The system
Unless assembly is an option, this translates to launching moves the dish on a n extendable boom relative to the
a 3D printer the size of a space station to print a space print head.9
station. To transport a 3D printer of that size to space is
cost prohibitive for both its mass and volume. Instead, a Currently, none of these concepts feature a prototype 3D
relatively small printer that is not restricted to its own printer that is both functioning and general use such that
build volume is ideal. Understanding this problem, many it can create a variety of structures larger than itself.
institutions such as NASA, AFIT, Redwire, Mitsubishi, Either there is no working prototype (NASA and AFIT)
and others have described promising solutions to create or the design is only capable of printing a single type of
a relatively small printer with a build volume larger than structure (AFIT, Redwire, Mitsubishi).5,9,10,15 The goal of
this research is to develop and demonstrate an improved
itself.
general use system for creating any large structure in
space.
NASA’s concept utilizes robotic arms to grab onto
printed structure and move the print head. The system

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METHODS in the Z axis. This also means that an initial segment of
this track is required to start the system printing.
Defining the Problem
The first challenge for 3D printing any giant structures
in space, evident in the above concepts, is making a
printer that moves in space relative to the printed
structure. This allows a printer to create something
outside of its own volume. The second challenge is
ensuring that the 3D printer can create any large structure
such that it is general use. Together, the total challenge
is creating a printer that can move in space relative to the
printed structure without limiting what the printed
structure can be.

Solution
The solution chosen for this research is similar to that of
the designs in relevant literature, such that it can attach
onto a previously printed structure. This avoids using
any thrusters that would require a constant supply of fuel.
What’s unique about the 3D printer outlined in this paper
is that it attaches to a consistent printed track physically
connected to the complex structure that is also being
printed. Having a track to hold onto prevents the
complexity of grabbing onto the varying shapes of the
structure and allows a simple movement mechanism.
Second, replacing the Z mechanism with a printable
track allows the Z axis to be extended infinitely. Lastly,
since the track connects to any complex structure the Figure 1: 3D Printed Rectangular Track/Rack with
printer is not limited in the shapes it can print. This Threaded Surface and Slots
feature allows the printer to be general use.
Initial Concept Test
To ensure precise Z movement along the track, a central After determining the mechanism of the concept, a small
threaded worm interfaces with a corresponding threaded mockup visible in Figure 2 was created to confirm that a
surface on a rectangular track or rack creating a worm - 3D printed worm-rack would work with the extra friction
rack system. Two sets of guide wheels follow on each as a replacement for the normal Z mechanism. A
side of this rectangular track along slots visible in Figure common hobby stepper motor was used in addition to a
5. gear system with a 2:1 gear ratio. A set of guide wheels
was also added to interface with the slots in the track and
The worm-rack allows for more precise movement maintain linear movement. After verifying the function
because it requires more turns compared to a similarly of the mechanism, work could then begin on making the
sized traditional gear-rack mechanism to move the rack final structure, hardware, software, calculations, and
the same distance. This means the same stepper motor adjustments.
using a worm-rack can make finer adjustments which
translates to finer Z adjustments. Precise Z movement is
important for 3D printing since layers usually range
between 0.12 to 0.2 mm thick. Any variation in layer
height creates inaccuracies in the part that could translate
to failed prints. Additiona lly, the Z mechanism was
placed in the corner of the build area. This allows for
improved stiffness in the mechanism and again allows
for more accurate adjustments. An important note for the
design is that it lacks a traditional build plate. This allows
the printer to extend parts infinitely without obstruction

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 Figure 2: Z Mechanism with Worm-Rack System
for Concept Test

Printer Structure
For the Z mechanism design, the Z movement of the Figure 3: Concept CoreXY 3D Printer with Z-
track (the build plate) is provided with an independent Mechanism
motor. As a result, a printer that moves the build plate in With sketches and the printer in hand, work began
the Z direction with an independent motor is necessary designing the system in Fusion 360 with the
for the mechanism’s integration. The two printer types measurements of the Tronxy. The design reused most of
possible to integrate with such a Z mechanism are a robot what the Tronxy already included but removed the Z
arm with a printer head attachment or a CoreXY printer. mechanism lead screws and build plate. In their place,
Ideally, a robotic arm would be used to allow for the the new track mechanism was integrated mirroring
most freedom moving along the track but for this largely what was created in the initial concept test but
research such a system was cost prohibitive. That left a with slight changes for integrating with the Tronxy.
CoreXY printer as the only option to demonstrate the
proof of concept. Instead of a hobby stepper motor, the worm was changed
to be powered directly by the Tronxy’s NEMA (National
The chosen printer for the system was the Tronxy X5SA Electrical Manufactures Association) 17 stepper motor,
Pro. This choice mainly came down to cost. With a to improve precision and power.7 To ensure the accuracy
printer chosen, design sketches for the final design were of the printed threads, the worm utilized large threads
created. These are visible in Figure 3 and showcase the with a maximum 45° overhang that could easily be 3D
proposed Z mechanism track with a mock space station printed. This meant that the corresponding geared
attached. surface of the track could also be easily 3D printed,
visible in Figure 1. The thread angle was kept as small as
possible while mainta ining the thread thickness to
decrease the travel of the rack with every revolution and
to increase the accuracy with every movement of the
stepper motor. The diameter of the worm was also
carefully managed to allow it to extend beyond the

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stepper motor and into the track but not so deep that it
would interfere with the grooved tracks for the guide
wheels.

As seen in Figure 1, the track mirrored the design of a

piece of T-channel aluminum with the addition of a
geared surface that corresponded with the worm . The
track was cut into sections at points that allow for
sections of track to be stacked without any change in the
thread pattern. This is important to allow the system to
print infinitely. Since all track sections end at a set point
in the pattern of the thread, additional sections are easily
added. On the backside of these tracks is a flat face that
easily allows for structures to be printed from it. Since
the track operates in the corner of the printer, the area of
the print bed is maximized.

The guide wheels were reused from the initial concept.

However, instead of six wheels, the design was changed
to four. Reducing the number of wheels provided
improved tolerance for the system. This allowed the Figure 4: Z Mechanism with Guide Wheels and
system to function even with slight inconsistencies in the Worm Mounted to Printer
3D printed track.
Printer Electronic Hardware
Next, parts were designed to mount the Z motor After noticing one of the integrated stepper drivers for
mechanism, including both the worm and guide wheels, the procured printer no longer worked, an Arduino
to the rest of the printer. Careful measurement of the system was chosen as a replacement since team members
Tronxy’s hot end path ensured that the Z mechanism had previous experience creating a DIY 3D printer with
remained out of the way when printing and that the track it.
was within the normal build plate area so it could be
extended. T-channel screws were re-used from the The chosen microcontroller was an Arduino Mega with
Tronxy to attach the entire mechanism to the frame of an ATMEGA2560-16AU chip. This chip offers 54
the printer. The worm was placed above the stepper Digital I/O (Input/Output) pins and 16 analog pins
motor knowing that over time gravity might otherwise allowing for easy feature integration.6 On top of the
try to pull it off. With this configuration, the force of Arduin Mega a stepper driver RAMPS (RepRap Arduino
gravity always kept the worm attached to the stepper Mega Pololu Shield) board was added.12 The RAMPS
motor. This assembly is visible in Figure 4. board is a modular board that can attach on top of the
Arduino Mega, hence the “shield” in the name. 12 This
All structural parts not reused from the Tronxy or the modular board includes multiple attachments for hot
guide wheels were printed on the Creality Ender 3 V2. ends, stepper drivers, heated beds, end stops, etc. There
are redundant aspects across the board allowing for ease
of customization. The board chosen was version 1.4, a
version commonly modified and used in printers
developed by Prusa Research and UltiMaker.12 This
board was also used as the main hardware to base Marlin
software from (an open-source software developed by
RepRap in 2011, commonly used in Prusas).4 This
background information assured that these parts would
be capable of accomplishing the abnormal nature of this
printer.

The stepper motors were SL42STH40-1684As re-

purposed from the Tronxy X5SA Pro. This stepper motor
is a variant of the NEMA 17 stepper motor, a commonly

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used stepper motor in the RepRap 3d printing
community.7 These stepper motors allow for high
precision with 200 steps per revolution and high torque
with each phase rated to draw 1.68 amps (3.36 amps
total) while providing a holding torque of 40 N*cm .7

Due to the high power and complex control nature of

stepper motors, a stepper motor driver is used to bridge
the link communication between the Arduino's digital
I/O pins and the stepper motor’s phases. Certain stepper
drivers can even provide increased accuracy with a
concept called micro-stepping that allows for refined
movement to 1/16, 1/32, and even 1/64 of a step on the
motor. The A4988 stepper driver is one of the most Figure 5. Stepper Drivers Potentiometer Circled in
popular stepper drivers known as a “bullet-proof Green
workhorse” by the RepRap community.1 It has the
capability to micro step to 1/16. The RAMPS board is A 12-volt power supply rated for 15 amps of current was
designed to hold up to five stepper drivers. Only four chosen to power all components of the printer. This
were necessary: one for each CoreXY motor, one for the provided more than enough power for all systems as
extruder, and one for the Z axis. there was no heated bed necessary for this setup, which
often draws high current. A 3D printed case was
Initially the A4988 driver was chosen based on its designed and printed to house all these electronics to
popularity and reviews, however after printing initial protect the system and make it easy to use, as seen in
designs it was evident the motors were causing a lot of Figure 6. The overall schematic for the design of
excess vibrations. These vibrations were created by the electronics is visible in Figure 7. There is some variation
stepper driver switching on and off at a high frequency from this design as the hardware purchased for the LCD
to ensure the motor did not go over the current limit set screen came in a bundled PCB including an attached
on the driver. The design of the frame allowed for these potentiometer, SD card reader, reset button, and
vibrations to shake the entire printer, which is not ideal backlight adjustment. This was connected to the RAMPS
when trying to print fast with high quality. Initially this board in the same location indicated in the schematic in
was not taken into consideration, but it was evident a Figure 7, however there was an adapter for the LCD
change needed to be made. These extraneous vibrations screen setup, using two ribbon cables to connect the two,
were reduced with newer stepper drivers that have a as seen in Figure 6.
mode in Marlin known as StealthChop. This mode
controls the motors by PWM (Pulse Width Modulated)
signals instead of current.16 These drivers are known as
trinamic drivers. One of the most popular is the
TMC2209. Fortunately, the TMC2209 was designed to
easily replace the A4988. This allowed all systems and
firmware to be easily re-configured. A connection to the
drivers over UART (Universal Asynchronous Receiver
Transmitter) was unsuccessful due to limitations of the
RAMPS board. However, this was not necessary as the
UART connection only provides the ability to adjust the
current limit of the drivers and change the mode of the
driver.17 The current limit can be adjusted from a
physical phillips screw potentiometer on the driver as
seen in Figure 5.17 Since we could not connect to UART,
the mode of the driver could not be changed. This was Figure 6. Electronics Setup
not a problem however as the default mode is
StealthChop, which was the desired mode.17

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 adjusted in real time. To accomplish this, in
Configuration_adv.h we defined
PROBE_OFFSET_WIZARD and BABYSTEPPI NG.
The values adjusted in the LCD screen would not be
saved when the system was restarted so it was important
to re-upload the firmware with the fine-tuned values
once they were found. The most crucial setting within
the Configura tion.h file is the steps per mm for the
different stepper motors. This allows the firmware to
translate the .gcode to precise movement in the stepper
motor and create dimensionally accurate parts. This was
crucial in our setup as any slight variation would
compound error in long prints possibly leading to a
binding of the worm-rack mechanism and a multitude of
other problems. The derivation for finding the correct
value for each stepper motor is described in the
Figure 7. Visual Schematic Calculations section.

Printer Firmware
As mentioned previously, Marlin Firmware was
developed by the RepRap community in 2011. 4 As an
open-source firmware, it has continued to be updated
with constant feature upgrades. The latest stable version
(2.1.2.2) was downloaded from the Marlin webpage
(https://marlinfw.org/). Arduino IDE version 2.3.2 was
used to open the Marlin firmware files, edit them, and
then upload to the Arduino Mega.

Within the Marlin firmware, there are two files:

Configuration.h and Configuration_Adv.h, both were
edited to conform with our printer's hardware and
provide easier calibration. In the Configuration.h the
hardware was defined, and other necessary parameters
adjusted. The use of the RAMPS 1.4, A4988 then
TMC2209 drivers, CoreXY configuration, 128x64 LCD,
SD card support, Z bed proximity leveling sensor were
all declared in the scope of the firmware. Other aspects
of the printer, however, required further modification
after initial tests. The X and Y end stops needed to be Figure 8. Z-axis Proximity Sensor Circled in Red,
inverted in the firmware as they were closed when not Nozzle Circled in Green.
pressed (output = 1) and open when pressed (output = 0).
Printer Slicer
This was changed by setting
E_MIN_ENDSTOP_INVERTING to True. The heated With firmware chosen, the last system needed was a 3D
bed was disabled as there is no heated bed in the system. printer slicer. A slicer turns a stereolithography model
This was set by setting TEMP_SENSOR_BED to 0. The (.stl) into a movement path for the 3D printer (.gcode).
position of the Z proximity sensor from the nozzle There are many options available on the market that all
needed to be defined. An image of the hot end assembly do mostly the same thing except for a few differences.
can be seen in Figure 8, displaying the sensor and nozzle For this project Cura was chosen for its advanced feature
position. The offset distance was found initially by set and its many available presets for different 3D
estimating with a caliper the offset in the X, Y, and Z printers.18 Importantly, one of these presets was for the
direction. The Z calibration wizard was enabled to refine Tronxy X5SA Pro. This reduced the overall fiddling with
the Z offset from the LCD menu eliminating the need to test para meters. The slicer was also used to adjust the X
adjust then re-upload the firmware. Baby stepping in the and Y offset of the printed track on the virtual print bed.
X, Y, and Z axis was also enabled so the offsets could be

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Calculations RESULTS AND DISCUSSION
After building the system, it now had to function. Usin g This system successfully demonstrated the track-based Z
the known steps per revolution of the stepper motor and axis mechanism by extending the initial track segment
pitch of the worm, the correct steps per millimeter were over 125 mm while printing a cylinder (space station)
calculated using Equations 1 and 2 for the Z mechanism. beside the track at the same time. The triangular cutout
of the cylinder, viewable in Figure 9, is a necessary
initial feature when printing in a non-micro-gravity
(1) environment to limit the overhang of the print. In space
this may not be necessary. While the system completed
the print, it did so with some clear inconsistencies in the
XY plane that caused the print to slightly layer shift over
(2) time. This phenomenon is commonly known as Z
wobble.8 This is presumed to be caused by sligh t
where ms = stepper motor steps; mms = stepper motor
misalignments of the initial print with the worm or the
micro steps; rev = revolutions of the stepper motor; and
stepper motors skipping steps. The consistent pattern on
p = pitch (mm of translational movement / revolution of
the print in Figure 9 is due to the Z axis moving more or
the stepper motor). less than the desired layer height of 0.12mm. This
phenomenon is commonly known as Z-banding. 8 The Z-
A similar method was used to calculate the correct steps
banding is presumed to be caused by inconsistencies in
per mm for the X, Y, and extruder stepper motors. The
the 3D printed worm's pitch. Another cause may be the
circumference of the gear that contacted the belt or
rubber guide wheels not having a constant circumference
filament was used instead of pitch to translate from steps
when moving across the track and suddenly increasing
per revolution to steps per mm. The circumference
their rolling resistance. Some possible solutions are to
provided us with a measurement of translation
precisely ma chine the worm out of metal, improve
movement in relation to revolution (mm/ revolution of
tolerances between rack and worm, or manually adjust
the stepper motor). Once these values were calculated
the gcode to account for the consistent pattern of change
they were input into the firmware.
in Z axis movement.
Adjustments
A valid criticism of the work conducted in this section is
One of the most crucial aspects for this printer to that while the demonstration does prove the Z axis
function is the precise placement of the print so that the mechanism working on earth, it does not necessarily
track joins with the existing track. To find the correct prove its function in its intended microgravity
placement spot, the approximate location of the printed environment. While that statement is true, there is
track was measured using calipers. This estimated nothing about the function of the system that would
location was then input into Cura’s virtual print bed, and inherently change in a microgravity environment. The
its output location was tested. When placement was off, system has even been tested to function upside down. So,
the distance offset was measured with calipers and
reinput into the location in Cura. Eventually this
reiterative process a llowed the printed track to join
seamlessly with the existing track. The Z offset was
found in a similar way to above but instead with input
into the firmware.

The next big challenge was the quality of the printer. For
this system to work it requires the printed track to be
dimensionally accurate without extreme variations. To
improve printer quality, additional adjustments were
made to ensure the structure and resulting printed parts
were square. Additional rigidity was added by re-
assembling the printer onto its original frame to reduce
large vibrations. With fine iteration and tweaking the
system eventually functioned as intended.

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while the criticism is true, with limited resources this is 3D printer also allows for the easy repair of structures by
entirely sufficient as a demonstration of the concept. simply moving back and forth along the track. This
opens the possibility for the system to be used as an
orbital repair robot. Future work could also attempt to
3D print conductive materials to integrate power system
directly into the structure. Other possible applications
also include robot replication. If printing electronic
components becomes a possibility, a similar system with
multi-material capability could potentially even print a
copy of itself.

Acknowledgements
This work was supported by the United States Air Force
Academy Astronautical Engineering Department and
Blue Horizon Rocketry.

The views expressed in this article, book, or presentation

are those of the author and do not necessarily reflect the
official policy or position of the United States Air Force
Academy, the Air Force, the Department of Defense, or
the U.S. Government.

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