The current clamp assembly (shown for reference) has a required kick load of 125 lbf. We understand that this requirement may be unfeasible given ABS material and the size limitations, but try to make the designs as strong as possible. Maximum loads from mechanical properties we have obtained so far from ABS parts made by FDM are as follows:
You must include:
- STL version
- Description of your design
You are encouraged to include:
- Native CAD file format
- STEP or IGES version
CHAMP figures of merit:
The following figures of merit will be used by NASA to determine which CHAMP design is determined as the most successful and is to be printed on the ISS.
1. Total Material Usage
a. ISS has established a maximum amount of ABS plastic allowed within the pressurized volume due to outgassing issues.
2. Number of prints required to complete each CHAMP
a. Astronaut time is valuable and sparse on the ISS
3. Hand Rail Connection
a. Ease of attachment
b. Ease of removal
c. Stability of attachment
- Slippage along handrail length
- Rotation about handrail
- Inadvertent disconnect
4. Seat Track Connection
a. Consistent with provided dimensions.
ISS Additive Manufacturing Capability:
- Print Volume (inches): 2.36 x 4.72 x 2.36 (X-Axis) x (Y-Axis) x (Z-Axis = extrusion direction or “vertical”)
- Material: ABS Plastic
- Nozzle Opening (inches): 0.015
- Minimum Layer Height (inches): 0.01
- Print Resolution (inches): 0.04
The CHAMP must at minimum meet the following requirements:
1. Shall be capable of providing a rigid connection to the handrail as defined above.
2. Shall provide a seat track interface as defined above.
3. Shall conform to the following sharp edge human factors
- Exposed edges 0.25 in thick or greater shall be rounded to a minimum radius of 0.12 in.
- Exposed edges 0.12 to 0.25 in thick shall be rounded to a minimum radius of 0.06 in.
- Exposed edges 0.02 to 0.12 in thick shall be rounded to a full radius.
- The edges of thin sheets less than 0.02 in thick shall be rolled or curled.
- Shall not extend beyond 1” from the cross-sectional perimeter of the handrail once installed and considered ready for use.
- Shall not extend beyond 5” along the handrail long axis.
5. If multiple parts are utilized, each much connect without the need of additional tools or materials. This applies to assembly, installation, removal and disassembly.
6. All design models shall be delivered as .stl files with a suitably fine mesh accurate enough to convey design intent (a .stp file will be required from the top three place designs as well).
7. Directions specifying build orientation shall be provided along with the design models. Axis nomenclature is found below in the ISS Additive Manufacturing Capability section.
ENTERING THE COMPETITION
The Challenge is open to everyone except employees and families of GrabCAD and the Sponsor. Multiple entries are welcome. Team entries are welcome.
By entering the Challenge you:
1. Accept the official GrabCAD Challenges Terms & Conditions.
2. Agree to be bound by the decisions of the judges (Jury).
3. Warrant that you are eligible to participate.
4. Warrant that the submission is your original work.
5. Warrant, to the best of your knowledge, your work is not, and has not been in production or otherwise previously published or exhibited.
6. Warrant neither the work nor its use infringes the intellectual property rights (whether a patent, utility model, functional design right, aesthetic design right, trademark, copyright or any other intellectual property right) of any other person.
7. Warrant participation shall not constitute employment, assignment or offer of employment or assignment.
8. Are not entitled to any compensation or reimbursement for any costs.
9. Agree the Sponsor and GrabCAD have the right to promote all entries.
If you think an entry may infringe on existing copyrighted materials, please email firstname.lastname@example.org
SUBMITTING AN ENTRY
Only entries uploaded to GrabCAD through the "Submit entry" button on this Challenge page will be considered an entry. Only public entries are eligible.
We encourage teams to use GrabCAD Workbench for developing their entries.
Entries are automatically given the tag "handrailclamp" when uploading to GrabCAD. Please do not edit or delete this tag. Only entries with valid tag will participate in the Challenge.
AWARDING THE WINNERS
The sum of the Awards is the total gross amount of the reward. The awarded participant is solely liable for the payment of all taxes, duties and other similar measures if imposed on the reward pursuant to the legislation of the country of his/her residence, domicile, citizenship, workplace, or any other criterion of similar nature. Only 1 award per person.
All winners will be contacted by the GrabCAD staff to get their contact information and any other information needed to get the prize to them. Payment of cash awards is made through PayPal. All team awards will be transferred to the member who entered the Challenge.
We will release the finalists before the announcement of the winners to give the Community an opportunity to share their favorites in the comments, discuss concerns, and allow time for any testing or analysis by the Jury. The Jury will take the feedback into consideration when picking the winners.
Winning designs will be chosen based on the Rules and Requirements.
- This Challenge ends on February 17, 2015 (11:59pm UTC).
- Winners will be announced by March 17, 2015.
Void where prohibited.
$2,000 total prize pool
The International Space Station’s 3-D printer has manufactured the first 3-D printed object in space, paving the way to future long-term space expeditions. The object, a printhead faceplate, is engraved with names of the organizations that collaborated on this space station technology demonstration: NASA and Made In Space, Inc., the space manufacturing company that worked with NASA to design, build and test the 3-D printer.
This image of the printer, with the Microgravity Science Glovebox Engineering Unit in the background, was taken in April 2014 during flight certification and acceptance testing at NASA's Marshall Space Flight Center in Huntsville, Alabama, prior to its launch to the station aboard a SpaceX commercial resupply mission. The first objects built in space will be returned to Earth in 2015 for detailed analysis and comparison to the identical ground control samples made on the flight printer prior to launch. The goal of this analysis is to verify that the 3-D printing process works the same in microgravity as it does on Earth.
The printer works by extruding heated plastic, which then builds layer upon layer to create three-dimensional objects. Testing this on the station is the first step toward creating a working "machine shop" in space. This capability may decrease cost and risk on the station, which will be critical when space explorers venture far from Earth and will create an on-demand supply chain for needed tools and parts. Long-term missions would benefit greatly from onboard manufacturing capabilities. Data and experience gathered in this demonstration will improve future 3-D manufacturing technology and equipment for the space program, allowing a greater degree of autonomy and flexibility for astronauts.
For more information, visit the website at www.nasa.gov/3Dprinting