The On-Demand Multimaterial Manufacturing (ODMM) Project will pursue the commercial development of hybrid (additive-subtractive) manufacturing prototype units for potential demonstration aboard the ISS. The Fabrication Laboratory from Techshot, Inc., which uses bound metal additive manufacturing (BMD) to extrude a polymer/metal feedstock blend, is the primary system being pursued by ODMM. The "green" (low-density) part is then moved into a furnace, where the polymer constituents are removed and the remaining metal (Titanium-64) is sintered. The FabLab furnace was able to produce "challenge parts" that met dimensional requirements and material test specimens that met key performance parameters of tensile strength, elongation, and density.

FabLab has the potential to expand the material processing capability to various metals as well as polymers, with the vision of providing a multi-material capability for future missions. Once the technologies and accompanying part inspection and certification methodologies are proved on ISS, they can be transitioned to future platforms to reduce logistics and enhance crew safety through point of use manufacturing.

The primary goal of ODMM through FY24 is to mature the aforementioned on-demand manufacturing system for a flight demonstration on ISS, where the feasibility of manufacturing metal parts in low-gravity can be demonstrated.

In addition, ODMM is investing in recycling, reuse, and outfitting for infusion into habitats and lunar surface logistics reduction.

ODMM was closed administratively at the end of FY23. The nascent technologies under development will evolve in the future, should the project be resumed. The printer module will be repurposed by the On-Demand Manufacturing of Electronics project.

The current International Space Station (ISS) logistics model is heavily dependent upon Orbital Replacement Units (ORUs) for system-based repair and maintenance. The logistics support is a significant challenge for extended human operations in space, especially for missions beyond Low Earth Orbit (LEO) where timely resupply or abort in the event of emergency would not be possible. An on-demand manufacturing capability would significantly reduce mission risk and logistical requirements while enabling Earth independent human spaceflight.

By enabling the fabrication of necessary tools, parts, and equipment on-demand, without requiring replenishment from Earth, in-space manufacturing has the potential to transform long-duration and deep space missions. As a result, space missions may be more sustainable and flexible while also being significantly less expensive and difficult. Additionally, the capacity to produce parts in space may open up new space exploration prospects, such as the construction of large structures or satellites that are too big to fit into a standard payload fairing. In conclusion, in-space manufacturing has the potential to significantly improve the capabilities of long duration and deep space missions and enable the next phase of human exploration beyond Earth's orbit.