FAMU researchers trailblaze in-space 3D printing

According to Florida A&M University (FAMU), breakthrough research in advanced 3D printing technology could fundamentally transform how astronauts sustain themselves during long-duration space missions, eliminating dependence on Earth-supplied materials and enabling on-demand manufacturing in space.

The pioneering work, led by Professor Subramanian Ramakrishnan from the Department of Chemical and Biomedical Engineering at the FAMU-FSU College of Engineering, has secured $5 million in NASA funding to develop next-generation materials critical for future space exploration.

“Imagine while on a space mission having the ability to print sensors, radiation shields, or even functional tissues as the mission progresses,” said Ramakrishnan. “This capability could change the space exploration paradigm, making missions more sustainable and adaptable to unforeseen challenges.”

Materials for space manufacturing

Ramakrishnan’s team is developing specialized 2D materials called MXenes, along with metallic and semiconducting nanoparticles, to create advanced inks specifically designed for 3D printing in extraterrestrial environments.

“These advanced inks are used to print everything from sensors that detect gases and strain, to antennas, radiation shielding, and flexible electronic circuits,” said Ramakrishnan. “They are especially important for 3D printed materials used on space missions.”

This research represents a crucial step toward in-space manufacturing (ISM), empowering astronauts to produce what they need while in orbit rather than relying on materials transported from Earth.

Extraterrestrial resources

Among the most promising innovations is the utilization of lunar and Martian soil—known as regolith—to create specialized printing materials for future Moon and Mars missions. This approach turns local resources into valuable construction materials, potentially enabling sustainable habitation on other worlds.

The interdisciplinary team collaborating on this research includes Satyanarayan Dev from FAMU’s Department of Biological Systems Engineering, Richard Liang from Florida State University, and Margaret Samuels from NASA’s Goddard Space Flight Center.

“This system has the critical capability for us to complete the manufacturing of precise sensor patterns in a single step to ensure high-quality device integration and on-demand design and manufacturing,” said Ramakrishnan.

Precision printing

The researchers have developed an innovative technique called Electrohydrodynamic (EHD) printing, which uses electric fields to precisely deposit nanoparticles for flexible electronic sensor applications.

“By combining this printing technique with laser curing, we can rapidly manufacture the sensors and speed up the manufacturing process,” said Ramakrishnan. “This streamlined approach is crucial for future space missions, especially when working on the International Space Station.”

To advance their capabilities, the university has acquired an advanced nScrypt 6-axis 3D printing system through an additional $700,000 National Science Foundation grant. This specialized equipment can create intricate designs on curved surfaces, particularly valuable for aerospace and medical device applications.

“We are experimenting with innovative ink formulations and techniques. The equipment is helping us produce new and exciting next-generation sensors for NASA,” said Ramakrishnan.

Biomedical frontiers in microgravity

Complementing the materials research, Co-director and Assistant Professor Jamel Ali is investigating how human cells self-assemble in microgravity environments similar to those on the Moon and Mars.

Ali’s team studies the behavior of 3D printed tissues in space with implications for therapeutic cell expansion and regenerative medicine. His collaborators include Emily Pritchard from the FSU Medical School and researchers at the Mayo Clinic in Jacksonville, working in partnership with NASA’s Kennedy Space Center.

The research addresses the unique challenges of 3D printing biological materials on curved surfaces, with applications that extend far beyond space exploration into medical innovations that could benefit patients on Earth.