A comprehensive review on metal laser additive manufacturing in space: Modeling and perspectives

Additive Manufacturing marks a transformative advancement in space exploration, where customization and efficient resource use are paramount. Metal additive manufacturing, specifically using the directed energy deposition process with wire feedstock, addresses the limitations of polymer-based Fused Filament Fabrication, which has been the primary focus of space missions until now. Metal additive manufacturing produces stronger metallic components and optimizes material usage, which is essential for prolonged space missions. Moreover, employing lasers as the heat source in additive manufacturing provides high precision, control, and reduced electromagnetic interference, which is crucial for operating in microgravity and electronic-sensitive environments. This review focuses on laser-based metal additive manufacturing in space exploration, highlighting the pivotal role of numerical simulations in case of limited access to experiments in space. These simulations are vital, cost-effective tools for predicting component quality, enhancing reliability, and optimizing manufacturing parameters in space-based additive manufacturing. By addressing the unique challenges of space additive manufacturing, metal additive manufacturing technologies promise to revolutionize space missions, reducing development costs and time while fulfilling stringent requirements.