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Combining polymers with small amounts of stiff carbon-based nanofillers such as graphene or graphene oxide is expected to yield low-density nanocomposites with exceptional mechanical properties. However, such nanocomposites have remained elusive because of incompatibilities between fillers and polymers that are further compounded by processing difficulties. Here we report a water-based process to obtain highly reinforced nanocomposite films by simple mixing of two liquid crystalline solutions: a colloidal nematic phase comprised of graphene oxide platelets and a nematic phase formed by a rod-like high-performance aramid. Upon drying the resulting hybrid biaxial nematic phase, we obtain robust, structural nanocomposites reinforced with graphene oxide. Reinforcing polymers with carbon-based nanofillers is non-trivial due to incompatibilities between matrix and filler. Here, the authors report highly reinforced graphene oxide–aramid nanocomposites utilizing a water-based hybrid biaxial nematic mixture.

A new chapter of space exploration is opening with future long-duration space missions toward the Moon and Mars. In this context, the European Space Agency is developing out-of-the-earth manufacturing abilities, to overcome the absence of regular supplies for astronauts’ vital needs (food, health, housing, energy). Additive manufacturing is at the heart of this evolution because it allows the fabrication of tailorable and complex shapes, with a considerable ease of process. Fused filament fabrication (FFF), the most generalized 3D printing technique, has been integrated into the International Space Station to produce polymer parts in microgravity. Filament deposition printing has also a key role to play in Li-ion battery (LIB) manufacturing. Indeed, it could reduce manufacturing cost & time, through one-shot printing of LIB, and improve battery performances with suitable 3D architectures. Thus, additive manufacturing via FFF of LIB in microgravity would open the way to in-space manufacturing of energy storage devices. However, as liquid and volatile species are not compatible with a space station-confined environment, solvent-free 3D printing of polymer electrolytes (PEs) is a necessary step to make battery printing in microgravity feasible. This is a challenging stage because of a strong opposition between the mechanical requirements of the feeding filament and electrochemical properties. Nowadays, PE manufacturing remains a hot topic and lots of strategies are currently being studied to overcome their poor ionic conductivity at room temperature. This work firstly gives a state of the art on the 3D printing of LIBs by FFF. Then, a summary of ionic conduction mechanisms in PEs permits to understand the several strategies studied to enhance PEs performances. Thanks to the confrontation with the specifications of FFF printing and the microgravity environment, polymer blends and composite electrolytes turn out to be the most suitable strategies to 3D print a lithium-ion polymer battery in microgravity.

Structured lead zirconium titanate (PZT)–epoxy composites are prepared by dielectrophoresis. The piezoelectric and dielectric properties of the composites as a function of PZT volume fraction are investigated and compared with the corresponding unstructured composites. The effect of poling voltage on piezoelectric properties of the composites is studied for various volume fractions of PZT composites. The experimentally observed piezoelectric and dielectric properties have been compared with theoretical models. Dielectrophoretically structured composites exhibit higher piezoelectric voltage coefficients compared to 0–3 composites. Structured composites with 0.1 volume fraction of PZT have the highest piezoelectric voltage coefficient. The flexural strength and bending modulus of the structured and random composites were analyzed using three-point bending tests.

Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS). Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.

There is an imperative need to find sustainable ways to produce bisphenol A free, high performance thermosets for specific applications such as the space or aerospace areas. In this study, an aromatic tris epoxide, the tris(4-hydroxyphenyl)methane triglycidyl ether (THPMTGE), was selected to generate high crosslinked networks by its copolymerization with anhydrides. Indeed, the prepared thermosets show a gel content (GC) ~99.9% and glass transition values ranged between 167–196 °C. The thermo-mechanical properties examined by DMA analyses reveal the development of very hard materials with E′ ~3–3.5 GPa. The thermosets’ rigidity was confirmed by Young’s moduli values which ranged between 1.25–1.31 GPa, an elongation at break of about 4–5%, and a tensile stress of ~35–45 MPa. The TGA analyses highlight a very good thermal stability, superior to 340 °C. The Limit Oxygen Index (LOI) parameter was also evaluated, showing the development of new materials with good flame retardancy properties.

Spacecraft experience minimal mechanical loads in space, but with the development of reusable spacecraft for interplanetary exploration and repeated landings, structures will be subjected to increased mechanical stress. The impact of the space environment on the aging of adhesive materials used in space structures over long-term applications is not well understood. This study investigates two commonly used adhesives in spacecraft assembly, namely Scotch-Weld™ EC-2216 and Scotch-Weld™ EC-9323-2, under two aging conditions: (1) high-energy electron irradiation using a Van de Graaf accelerator, and (2) thermal vacuum cycling. The research evaluates the evolution of intrinsic adhesive properties and adhesion to CFRP (carbon fiber-reinforced polymer) and aluminum adherents before and after exposure to these environmental conditions through tensile tests, peel tests, double-cantilever beam (DCB) tests, and dynamic mechanical analysis (DMA).

Extensive global research efforts have focused on the exploitation of graphene for enhanced energy storage. Novel graphene-based composite material electrodes have been developed, in many cases with reports of outstanding performance. However, the development of these composites involve extremely complex and costly procedures/methods whose scalability and eventual commercial exploitation is extremely hard [1]. Within the present activity the use of graphene nanotechnology is exploited to manufacture electrodes for supercapacitors. The goal however is to achieve electrodes with increased specific energy density (compared to the currently commercially available products) using proven and simple manufacturing procedures that can easily be scaled-up and offer competitive products. The roadmap was developed under the framework of European Space Agency highlighting the main advantages brought up from this technology. The activity is separated in three parallel routes; the development and test planning of small–scale production of graphene based materials via the tape casting technology, the establishment of a reliable and low cost industrial production process (scale-up) for these materials and the development and testing of an energy storage demonstrator that shall incorporate the novel electrodes and exhibit their favorable characteristics in energy storage applications for use in space.

Photopolymers are promising materials for in-space manufacturing, whether for continuous extrusion or structural bonding. However, they must be processed as a liquid under high vacuum, which can alter viscosity, curing behavior, or mechanical properties. Furthermore, high outgassing can contaminate spacecraft surfaces. To study the influence of high vacuum on the resins in their liquid phase, Delo Katiobond GE680, Delo Katiobond OB678, Polymer-G EPV9511, and Loctite AA3301 LC were exposed to high vacuum. Outgassing was quantified for both liquid and cured samples. Viscosity increased in all resins, and UV-curing efficiency generally decreased. EPV9511 maintained stable mechanical properties, whereas the Delo and Loctite resins exhibited reduced stiffness at 45 °C. All resins exceeded 1% total mass loss in their liquid state, but cured GE680 and OB678 met low-outgassing criteria. GE680 and EPV9511 showed the highest vacuum stability and appear suitable for in-space processing when volatile components are minimized through pre-degassing.

The present work reports the production and characterization of polyetheretherketone (PEEK) nanocomposite filaments incorporating carbon nanotubes (CNT) and graphite nanoplates (GnP), electrically conductive and suitable for fused deposition modeling (FDM) processing. The nanocomposites were manufactured by melt mixing and those presenting electrical conductivity near 10 S/m were selected for the production of filaments for FDM. The extruded filaments were characterized for mechanical and thermal conductivity, polymer crystallinity, thermal relaxation, nanoparticle dispersion, thermoelectric effect, and coefficient of friction. They presented electrical conductivity in the range of 1.5 to 13.1 S/m, as well as good mechanical performance and higher thermal conductivity compared to PEEK. The addition of GnP improved the composites’ melt processability, maintained the electrical conductivity at target level, and reduced the coefficient of friction by up to 60%. Finally, three-dimensional (3D) printed test specimens were produced, showing a Young’s modulus and ultimate tensile strength comparable to those of the filaments, but a lower strain at break and electrical conductivity. This was attributed to the presence of large voids in the part, revealing the need for 3D printing parameter optimization. Finally, filament production was up-scaled to kilogram scale maintaining the properties of the research-scale filaments.

Aerospace composites are susceptible to barely visible impact damage (BVID) produced by low-velocity-impact (LVI) events. Fibre Bragg grating (FBG) sensors can detect BVID, but often FBG sensors are embedded in the mid-plan, where residual strains produced by impact damage are lower, leading to an undervaluation of the damage severity. This study compares the residual strains produced by LVI events measured by FBG embedded at the mid-plan and other through-thickness locations of carbon fibre reinforced polymer (CFRP) composites. The instrumented laminates were subjected to multiple low-velocity impacts while the FBG signals were acquired. The FBG sensor measurements allowed not only for the residual strain after damage to be measured, but also for a strain peak at the time of impact to be detected, which is an important feature to identify the nature and presence of BVID in real-life applications. The results allowed an adequate optical fibre (OF) embedding location to be selected for BVID detection. The effect of small- and large-diameter OF on the impact resistance of the CFRP was compared.