Vacuum Arc Plasma Coating for Polymer Surface Protection— A Plasma Enhanced In-Orbit Additive Manufacturing Concept

In-orbit additive manufacturing (AM) is a promising approach for fabrication of large structures. It allows to expand and accelerate human space exploration possibilities. Extrusion-based AM was demonstrated in zero gravity, while the realization of such a process in orbit-like vacuum conditions is currently under exploration. Still, a solution for protection of the UV and IR radiation sensitive polymers is needed in order to prevent their early mechanical failure under space conditions. Vacuum arc plasma based process is widely applied on earth for thin protective coating deposition. Its major advantage is its scalability—from tiny size used in electric propulsion to large scale coating devices. The usability of the vacuum arc process in space conditions was shown in electric propulsion applications in nano-satellites. In this work we discuss and demonstrate the integration of vacuum arc process as a post processing step after Fused Filament Fabrication (FFF) for additive manufacturing and functionalization of long polymer structures. Here we address the concept for technical realization, which integrates the vacuum arc into additive manufacturing process chain. More over we present a laboratory prototype, which implements this concept together with a use case, where a previously printed PEEK structure is coated with aluminum based coating suitable for UV radiation protection.