Developing in orbit manufacturing methods for sustainable composites for space applications

随着航天工业的发展，可持续性正日益成为人们关注的问题。但是，由于质量和环境限制而产生的空间应用的严格性能要求是一项重大挑战。目前的航天器都是用不可回收的材料制造的，要么报废，要么报废。这种解决方案对绕地飞行任务来说是令人满意的；但是，长期或无限期的任务可能必须就地使用/重新使用现有材料。该项目旨在开发和研究一种在轨制造方法，作为当前范式的潜在替代方案。一种成功的方法可以释放出制造大型、高效结构的能力，而不会受到发射和制造新材料的惩罚。虽然该博士学位的范围主要集中在空间应用上，但这种方法也可能对复合材料的地面可持续性产生重大影响，目前复合材料广泛应用于航空航天和风能领域。所提出的概念结合了WrapToR制造方法的结构效率和非连续纤维复合材料的可回收性，以及由HiPerDiF对准过程实现的性能。到目前为止，还没有一个小组证明了一个系统同时具有相当的结构效率和可回收性。为了发展这一概念，该项目旨在解决以下挑战：1。确定和开发适合于空间应用和制造的不连续纤维热塑性复合材料。2. 开发一种能够将对齐的HiPerDiF磁带和热塑性塑料整合成可用的长丝原料的方法。3. 修改WrapToR工艺，使其与热塑性输入材料兼容。

Sustainability is becoming an increasing concern for the space industry as it grows. However, the strict performance requirements of the space application arising from mass and environmental constraints pose a significant challenge. Current spacecraft are made using non-recyclable materials and are either demised or written off at their end-of-life. This solution has been satisfactory for earth-orbiting missions; however, in-situ use/reuse of existing material may become obligatory for long-duration or indefinite missions.This project aims to develop and investigate an in-orbit manufacturing method as a potential alternative to the current paradigm. A successful method could unlock the ability to create large, efficient structures without the penalties associated with the launch and manufacture of virgin material. While the scope of this PhD is primarily focused on space applications, such a method could also have significant implications for the terrestrial sustainability of composites, which are currently widely used in the aerospace and wind energy sectors.The proposed concept combines the WrapToR manufacturing method's structural efficiency with discontinuous fibre composite's recyclability and performance enabled by the HiPerDiF alignment process. To date, no group has demonstrated a system simultaneously capable of comparable structural efficiency and recyclability. To develop this concept, the project aims to tackle the following challenges: 1. Identify and develop a discontinuous fibre thermoplastic composite suitable for space application and manufacturing. 2. Develop a method capable of consolidating aligned HiPerDiF tapes and thermoplastic into a usable filament feedstock. 3. Modify the WrapToR process to be compatible with a thermoplastic input material.