Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes

Research output: Contribution to journalArticleResearchpeer review

Authors

  • Jan Raffel
  • Torben Boḧm
  • Jan Dus̈ing
  • Marvin Roḧl
  • Carsten Schilde
  • Ajay P. Malshe
  • Ludger Overmeyer
  • Christoph Lotz

External Research Organisations

  • Laser Zentrum Hannover e.V. (LZH)
  • Technische Universität Braunschweig
  • Purdue University
View graph of relations

Details

Original languageEnglish
Article number121001
JournalJournal of Manufacturing Science and Engineering
Volume146
Issue number12
Early online date19 Sept 2024
Publication statusPublished - Dec 2024

Abstract

3D printing is one of the key technologies in space exploration. The disparity in gravitational forces between Earth and space presents both challenges and opportunities with regard to material handling. This article examines the potential of employing ultrasonic levitation as a handling tool for substrate-free additive manufacturing processes in microgravity environments. Through preliminary experiments, we demonstrate the feasibility of manipulating polymer powders using acoustic fields while concurrently melting the levitated material. Subsequent experiments conducted in our drop tower facility confirm our ability to manipulate particles with acoustic traps under microgravity conditions. Building upon these findings, we outline plans to further advance our research using an expanded acoustic levitation system capable of three-dimensional object manipulation. Our objectives include moving and orienting large components beyond the wavelength limit in microgravity, manipulating granular raw material while melting it in proximity to the print part, and achieving a semi-continuous fusion of print material with the print part. Therefore, we present an intelligent control strategy based on the results of a digital twin simulation. Furthermore, we utilize a stereo camera combined with computer vision as feedback for the control system to ensure precise handling of the manipulated objects and particles. This study represents a significant advance toward the realization of efficient substrate-free additive manufacturing processes in microgravity environments, with potential applications for in-space manufacturing. Ultimately, this could result in long-term space missions becoming less reliant on supply deliveries, thus reducing cost and additionally enabling faster response to unforeseen issues.

Keywords

    additive manufacturing, AI, digital twin, in-space manufacturing, laser processes, materials handling, microgravity, process engineering, reinforcement learning, simulation, ultrasonic levitation

ASJC Scopus subject areas

Cite this

Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes. / Raffel, Jan; Boḧm, Torben; Dus̈ing, Jan et al.
In: Journal of Manufacturing Science and Engineering, Vol. 146, No. 12, 121001, 12.2024.

Research output: Contribution to journalArticleResearchpeer review

Raffel, J, Boḧm, T, Dus̈ing, J, Roḧl, M, Schilde, C, Malshe, AP, Overmeyer, L & Lotz, C 2024, 'Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes', Journal of Manufacturing Science and Engineering, vol. 146, no. 12, 121001. https://doi.org/10.1115/1.4066335
Raffel, J., Boḧm, T., Dus̈ing, J., Roḧl, M., Schilde, C., Malshe, A. P., Overmeyer, L., & Lotz, C. (2024). Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes. Journal of Manufacturing Science and Engineering, 146(12), Article 121001. https://doi.org/10.1115/1.4066335
Raffel J, Boḧm T, Dus̈ing J, Roḧl M, Schilde C, Malshe AP et al. Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes. Journal of Manufacturing Science and Engineering. 2024 Dec;146(12):121001. Epub 2024 Sept 19. doi: 10.1115/1.4066335
Raffel, Jan ; Boḧm, Torben ; Dus̈ing, Jan et al. / Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes. In: Journal of Manufacturing Science and Engineering. 2024 ; Vol. 146, No. 12.
Download
@article{743c03cb630e4d96a9ebc55bbfa7a35f,
title = "Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes",
abstract = "3D printing is one of the key technologies in space exploration. The disparity in gravitational forces between Earth and space presents both challenges and opportunities with regard to material handling. This article examines the potential of employing ultrasonic levitation as a handling tool for substrate-free additive manufacturing processes in microgravity environments. Through preliminary experiments, we demonstrate the feasibility of manipulating polymer powders using acoustic fields while concurrently melting the levitated material. Subsequent experiments conducted in our drop tower facility confirm our ability to manipulate particles with acoustic traps under microgravity conditions. Building upon these findings, we outline plans to further advance our research using an expanded acoustic levitation system capable of three-dimensional object manipulation. Our objectives include moving and orienting large components beyond the wavelength limit in microgravity, manipulating granular raw material while melting it in proximity to the print part, and achieving a semi-continuous fusion of print material with the print part. Therefore, we present an intelligent control strategy based on the results of a digital twin simulation. Furthermore, we utilize a stereo camera combined with computer vision as feedback for the control system to ensure precise handling of the manipulated objects and particles. This study represents a significant advance toward the realization of efficient substrate-free additive manufacturing processes in microgravity environments, with potential applications for in-space manufacturing. Ultimately, this could result in long-term space missions becoming less reliant on supply deliveries, thus reducing cost and additionally enabling faster response to unforeseen issues.",
keywords = "additive manufacturing, AI, digital twin, in-space manufacturing, laser processes, materials handling, microgravity, process engineering, reinforcement learning, simulation, ultrasonic levitation",
author = "Jan Raffel and Torben Boḧm and Jan Du{\"s}ing and Marvin Roḧl and Carsten Schilde and Malshe, {Ajay P.} and Ludger Overmeyer and Christoph Lotz",
note = "Publisher Copyright: Copyright {\textcopyright} 2024 by ASME;",
year = "2024",
month = dec,
doi = "10.1115/1.4066335",
language = "English",
volume = "146",
journal = "Journal of Manufacturing Science and Engineering",
issn = "1087-1357",
publisher = "American Society of Mechanical Engineers(ASME)",
number = "12",

}

Download

TY - JOUR

T1 - Ultrasonic Levitation as a Handling Tool for In-Space Manufacturing Processes

AU - Raffel, Jan

AU - Boḧm, Torben

AU - Dus̈ing, Jan

AU - Roḧl, Marvin

AU - Schilde, Carsten

AU - Malshe, Ajay P.

AU - Overmeyer, Ludger

AU - Lotz, Christoph

N1 - Publisher Copyright: Copyright © 2024 by ASME;

PY - 2024/12

Y1 - 2024/12

N2 - 3D printing is one of the key technologies in space exploration. The disparity in gravitational forces between Earth and space presents both challenges and opportunities with regard to material handling. This article examines the potential of employing ultrasonic levitation as a handling tool for substrate-free additive manufacturing processes in microgravity environments. Through preliminary experiments, we demonstrate the feasibility of manipulating polymer powders using acoustic fields while concurrently melting the levitated material. Subsequent experiments conducted in our drop tower facility confirm our ability to manipulate particles with acoustic traps under microgravity conditions. Building upon these findings, we outline plans to further advance our research using an expanded acoustic levitation system capable of three-dimensional object manipulation. Our objectives include moving and orienting large components beyond the wavelength limit in microgravity, manipulating granular raw material while melting it in proximity to the print part, and achieving a semi-continuous fusion of print material with the print part. Therefore, we present an intelligent control strategy based on the results of a digital twin simulation. Furthermore, we utilize a stereo camera combined with computer vision as feedback for the control system to ensure precise handling of the manipulated objects and particles. This study represents a significant advance toward the realization of efficient substrate-free additive manufacturing processes in microgravity environments, with potential applications for in-space manufacturing. Ultimately, this could result in long-term space missions becoming less reliant on supply deliveries, thus reducing cost and additionally enabling faster response to unforeseen issues.

AB - 3D printing is one of the key technologies in space exploration. The disparity in gravitational forces between Earth and space presents both challenges and opportunities with regard to material handling. This article examines the potential of employing ultrasonic levitation as a handling tool for substrate-free additive manufacturing processes in microgravity environments. Through preliminary experiments, we demonstrate the feasibility of manipulating polymer powders using acoustic fields while concurrently melting the levitated material. Subsequent experiments conducted in our drop tower facility confirm our ability to manipulate particles with acoustic traps under microgravity conditions. Building upon these findings, we outline plans to further advance our research using an expanded acoustic levitation system capable of three-dimensional object manipulation. Our objectives include moving and orienting large components beyond the wavelength limit in microgravity, manipulating granular raw material while melting it in proximity to the print part, and achieving a semi-continuous fusion of print material with the print part. Therefore, we present an intelligent control strategy based on the results of a digital twin simulation. Furthermore, we utilize a stereo camera combined with computer vision as feedback for the control system to ensure precise handling of the manipulated objects and particles. This study represents a significant advance toward the realization of efficient substrate-free additive manufacturing processes in microgravity environments, with potential applications for in-space manufacturing. Ultimately, this could result in long-term space missions becoming less reliant on supply deliveries, thus reducing cost and additionally enabling faster response to unforeseen issues.

KW - additive manufacturing

KW - AI

KW - digital twin

KW - in-space manufacturing

KW - laser processes

KW - materials handling

KW - microgravity

KW - process engineering

KW - reinforcement learning

KW - simulation

KW - ultrasonic levitation

UR - http://www.scopus.com/inward/record.url?scp=85214123225&partnerID=8YFLogxK

U2 - 10.1115/1.4066335

DO - 10.1115/1.4066335

M3 - Article

AN - SCOPUS:85214123225

VL - 146

JO - Journal of Manufacturing Science and Engineering

JF - Journal of Manufacturing Science and Engineering

SN - 1087-1357

IS - 12

M1 - 121001

ER -