Continuous Wire Embedded 3D Printing for Sorbent Regeneration

NASA is seeking an advanced heater to replace the current heaters used in the carbon dioxide removal assemblies. The current SOTA spacecraft sorption system utilizes commercial off-the-shelf (COTS) resistive heaters coupled with conductive fins. These current heaters were not manufactured for use on spacecraft, and as such, are sub-optimal, particularly for planned deep space missions. These deep space missions will be power limited and therefore require a more efficient method of sorbent regeneration. To address this need, Mainstream proposes a method of embedding a heating element directly into the sorbent structure. This method will drastically reduce thermal contact resistance, reducing regeneration cycle time and total power input. In Phase I, Mainstream will formulate a zeolite paste capable of being 3D printed into a self-supporting structure, develop the process of embedding the heating elements into the structures, and demonstrate the fabrication of a zeolite structure with embedded heating elements. These tasks will lead to the ultimate goal of printing fully functional replacement sorbent beds with embedded heating elements for existing and planned spacecraft during the Phase II.