Operational Benefit of a 3D Printer in Future Human Mars Missions—Results from Analog Simulation Testing

The remote nature of human missions to Mars requires a different paradigm for how operations should be performed. In particular, there is a need for greater independence from Earth, and the ability to adapt to evolving scenarios: needs that can potentially be assisted by integrating 3D printing technology into a Mars mission. A 3D printer can enable the production, repair, and modification of tools on Mars to address needs that arise. A series of experiments were carried out on the AMADEE-18 Mars Analog Simulation to investigate the potential benefit of integrating a printer into operations. AMADEE-18 was a one-month-long activity which provided a high-fidelity test environment, including communication delays between simulated Mars and Earth. The experiments involved production, repair, and modification of custom-designed geological sampling tools using a 3D printer inside the Mars habitat. A set of modular procedures were used to integrate 3D printing into the flight plan and compare the operational performance between Earth-led and Mars-led operations. 17 planned printing runs were complete, with execution times recorded, and subjective feedback collected. The results showed the difficulty in scheduling 3D printing operations, with the requirement for numerous small tasks spread out over an extended period. It was identified that Earth-led operations were superior with regard to crew workload, as they provided a more convenient way to manage these small, infrequent tasks. In addition to the planned prints, there were 13 unplanned prints completed, including a vital replacement clip for an EVA suit, showing the adaptability and utility granted by a 3D printer. The geological sampling tool used in the experiments was a hybrid of printed plastic and high-quality printed metal produced on “Earth”. This hybrid design was shown to be successful and presents an avenue for future research. In addition to the field tests during the AMADEE-18 mission, a study about the contamination in geological samples caused by the 3D printed tools was performed. Therefore, the size distribution of the abrasion from the 3D printed plastic tools was assessed and their form characterized.