Title:

In-Space Incremental Sheet Forming

This project presents the design and development of a compact incremental sheet metal forming (ISF) machine engineered for operation aboard the International Space Station (ISS) in extreme temperature fluctuations under microgravity and vacuum conditions. This machine addresses the unique challenges surrounding in-space manufacturing capabilities by incorporating inventive solutions, allowing for on-demand fabrication of custom metal components. These challenges include ISS compatibility and regulation compliance, vacuum and microgravity performance, extreme temperature functionality, power efficiency and heat management, machine size, weight, noise optimization, and more. The machine includes a custom multi-axis positioning system for operating our interchangeable forming tool setup and an innovative clamping system. This, paired with control software, provides an accurate and precise sheet-forming process for numerous sheet-metal compositions and thicknesses. Early testing utilizes a vacuum chamber for monitored forming of various shaped geometries to display functionality without exceeding material limits. This machine has the potential to provide impactful advancements towards in-space manufacturing, while simultaneously reducing the cost and frequency of fundamental shuttle deliveries.

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