We are developing an on-demand direct metal printing technology that can utilize the unique advantages of manufacturing in a zero-gravity Low Earth Orbit (LEO) environment, to produce value-added next generation materials that are challenging to manufacture terrestrially. One such class of materials, covetics (nanocarbon-infused metals), are inherently difficult to produce on Earth but have great in-space and terrestrial commercial potential due to their enhanced physicochemical properties, such as higher thermal/electrical conductivity and higher strength at lower mass as compared to conventional wrought metals.Specifically, this talk will highlight an ongoing activity at Faraday to directly print composite nanowires via a pulse electro-codeposition approach. This activity has indicated that these composite materials can achieve a greater than 50% reduction in sheet resistance and a ~50% increase in mechanical strain compared to Cu foils. We will also discuss the opportunity to produce a wide range of material shapes by enabling a direct print apparatus that combines x,y,z control methods with an electro-codeposition printhead. If successful, we envision that the method to print next generation composite materials like ‘covetics’ has the potential to meet many of the electronics and space community’s needs by enabling in-space structural repairs, fabrication of new electronic components or sensors, or be utilized as heat exchanger composite materials.Acknowledgements: Faraday Technology acknowledges the NASA SBIR activities under 80NSSC22CA99.
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