FAMU-FSU College of Engineering professor to study 3D printing for space exploration with $5M NASA grant

Researchers at the FAMU-FSU College of Engineering will pioneer advanced composite materials and manufacturing technologies critical for future space missions through a $5 million grant from NASA.

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

The NASA grant was given to researchers from seven institutions. Florida A&M University will administer the grant on behalf of the FAMU-FSU College of Engineering.

Researchers will partner with faculty at Florida State University, including Richard Liang from the FAMU-FSU College of Engineering and Emily Pritchard from the FSU Office of the Provost. They will also work with Satyanarayan Dev from FAMU and Margaret Samuels from the Goddard Space Flight Center. Each has expertise in developing a system that can produce precise sensor patterns, integrating sensing materials and electrodes in a single step.

Ramakrishnan’s team mainly focuses on creating innovative materials. They are developing unique 2D materials called MXenes and metallic and semiconducting nanoparticles to develop special inks for 3D printing in space.

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

In-space manufacturing (ISM) aims to transform how we create components for space. The vision is to empower astronauts to manufacture what they need in orbit, making missions more sustainable and efficient rather than relying on materials and tools sent from Earth.

These distinctive materials have exceptional structural, physical and chemical properties, making them perfect for various applications, including energy storage, sensors, optoelectronics and even biomedical uses. They are crucial for space exploration but also have unique properties for specialized materials on Earth.

INNOVATION AND COLLABORATION
Ramakrishnan’s group wants to utilize lunar and Martian soil — also known as regolith — to create special inks that can be 3D printed into functional structures for future missions to Mars and the Moon.

“This system has the critical capability for us to complete the manufacturing of precise sensor patterns (both sensing materials patterns and electrode and connection patterns) in a single step to ensure high-quality of device integration and on-demand design and manufacturing,” Ramakrishnan explained.

The researchers have developed a new technique called electrohydrodynamic (EHD) printing. This method uses electric fields to precisely print nanoparticles, which can be used to create flexible electronic sensor applications.

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

NEXT-GENERATION PRINTING
In addition to the NASA grant, Ramakrishnan is leading a project funded by a $700,000 grant from the National Science Foundation to support purchasing specialized equipment designed for 3D printing on curved surfaces. Florida A&M University acquired an advanced nScrypt 6-axis 3D printing system that can create intricate designs tailored to various shapes, especially for applications in aerospace and medical devices.

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

The state-of-the-art printer can precisely dispense materials, allowing researchers to develop complex structures that conform to different surfaces.

BIOMATERIALS FOR SPACE
Co-Director and Assistant Professor Jamel Ali from the Department of Chemical and Biomedical Engineering at the college is leading research efforts to understand how human cells self-assemble in microgravity environments, such as those found on the Moon and Mars. His group is looking into the behavior of 3D-printed tissues in space to enhance therapeutic cell expansion and regenerative medicine. He works with collaborators, including researchers at the Mayo Clinic in Jacksonville, who work closely with NASA’s Kennedy Space Center on these pioneering projects.

His research group works with biomaterials and non-biomaterials to create guidelines that address the unique challenges of 3D printing on curved surfaces. This work could lead to innovations that go well beyond space exploration. They plan to incorporate electrohydrodynamic (EHD) printing techniques to develop semiconducting nanomaterials tailor-made for NASA’s needs.

IMPACTING THE FUTURE OF MATERIALS SCIENCE
The potential outcomes of the research extend far beyond NASA missions. The novel sensors, tissues and organs that have been developed could revolutionize fields like biomedicine and materials science, providing solutions that address pressing health challenges and contributing to the advancement of technology in various sectors.

With NASA’s backing and the integration of cutting-edge research practices, the FAMU-FSU College of Engineering is poised to play a pivotal role in the future of space exploration. This initiative represents a critical step in fostering sustainable operations for exploration missions, ensuring we can harness technology to meet our needs in real time.

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