Faraday Technologies

Faraday Technology will create an in-space manufacturing process to directly print next-generation covetic materials (nanocarbon-infused metals/alloys) in Low Earth Orbit (LEO) via an electro-co-deposition approach to leverage the unique capabilities of the International Space Station (ISS).

Created: 2022-09-03

Updated: 2024-10-03

Company - Faraday Technologies

Founded
Country: 1991; USA

Funding: Yes, ?

Website: http://www.faradaytechnology.com/

Product/Service

Classification: In-Space Manufacturing

Category: In-Space Manufacturing

Fields: Additive Manufacturing (3D printing)
Electronics
Orbital Microfabrication

Status: Development

First launch: Not announced

LEO Manufacturing of 3D Printed Covetic Nanomaterials for Advanced Electronics, 2021 SBIR Phase I

This program will develop an in-space material manufacturing approach to leverage the unique capabilities of the International Space Station.

Specifically, one such, exemplar novel class of material, covetics (nano-carbon-infused metals), are inherently challenging to produce terrestrially but have great commercial potential due to their enhanced physicochemical properties as compared to conventional metals, such as high thermal (50% higher than Cu), high electrical conductivity (40% higher than 6061 Al), and high strength (30% higher yield strength than Cu).

Therefore, Faraday Technology and the University of Texas in Dallas will develop a material manufacturing process to directly print these next generation covetic materials in Low Earth Orbit (LEO) via an electro-codeposition approach.

This work will build on the University of Texas's direct Cu printing platform which has been demonstrated at pre-commercial scale the potential to print large area circuit board lines utilizing a localized pulse electrodeposited (L-PED) technique.

Additionally, this work will build on Faraday's electro-code position process activities that include depositing carbon materials into copper. In Phase I we will establish the viability of directly printing covetic materials by developing the direct write hardware and the electro-codeposition electrolytes to deposit electrochemically reduced carbon materials into a copper matrix in an orientation opposite or perpendicular to gravity such that we can demonstrate at the lab scale, the potential to form covetic materials with enhanced electrical, thermal, and mechanical properties.

This demonstration would enable a preliminary market need assessment (Phase I) and zero gravity flight demonstration (Phase II), which could establish a commercial market for in-space manufacturing of these exciting covetic materials. If successful the results of the Phase I/II program will set the stage for LEO commercialization of this manufacturing process.

Climate Enhancing Resource Utilization Through Ultra-low-temperature, Electrolytic Carbon Dioxide Valorization on Mars, 2023 STTR Phase 1

Supporting human life on long-tern space exploration missions, such as manned missions to the surface of Mars, require sustainable resource utilization with minimal support from Earth. In response to this need, NASArsquo;s in-situ resource utilization (ISRU) mission was put in place to provide a sustainable infrastructure for long-tern missions, such as exploration of extraterrestrial planets.

One particular resource available on Mars is atmospheric carbon dioxide (CO2). CO2 makes up 95% of the atmosphere, providing an abundant resource for human explorers to take advantage of. For instance, CO2 can be electrochemically reduced into ethanol. Ethanol exists as a liquid on the Martian surface, allowing for relative ease of storage. Additionally, this chemical can be used as an energy source in fuel cells, and can act as a feedstock for material manufacturing. In Phase I, Faraday and UTSA will develop an electrochemical reactor capable of converting atmospheric carbon dioxide into ethanol at conditions commonly experienced on the Martian surface, such as low temperatures (-65deg;C average on Martian surface). Optimization of ethanol production will be performed through modifying the reactor design and the electrodes, with the goal of producing ethanol with high selectivity (gt;50%) with a low energy requirement for production of ethanol (0.047 g ethanol per watt-hour).

Additionally, Phase I will include a critical risk assessment for using naturally occurring perchlorate salts, which are found in the water on Mars, as the electrolyte in the electrochemical reactor. Alignment of this technology with future NASA and commercial missions to Mars is critical for successful integration, and with the help of our team, we will assess safety and system robustness metrics required for Phase II and beyond. In Phase II, we will work to scale up the production of ethanol, while also establishing the ability to process CO2 from atmosphere conditions similar to Mars.

Extraction and Utilization of Water and Gases from Icy Lunar Regolith, 2023 SBIR Phase I

NASA in-situ resource utilization (ISRU) mission is to put in place a sustainable infrastructure that will allow human habitation on Moon with minimal support from earth. One particular resource available on the lunar permanently shadowed regions (PSRs) is the icy regolith which consists of icy water and volatile components (e.g., H2S, NH3, SO2, C2H4, CO2, CH3OH, CH4). Recovered water and volatile components from the icy regolith could be used to support human life on the moon. For instance, water could be used as life support and propellant; volatile gases can be used to manufacture polythiols polymer, sulfur can be used in concrete, composites, batteries, space sealant, etc.

Faraday and the University of Kansas will demonstrate a high recovery scalable manufacturing platform for extraction of icy lunar regolith. In Phase I, Faraday and University of Kansas will develop a process to solubilize water and volatile gases from icy high-fidelity regolith simulant. Next, Faraday will utilize thermosensitive liquids to demonstrate the separation of pure water and a desorption process to remove the absorbed gases from the liquid. Finally, we will demonstrate regeneration of the thermosensitive liquids and show a plan to utilize recovered products in a way that reduced the cost of landing consumables on the lunar surface. The results of this investigation will provide a basis for transition planning and an alpha-scale semi-continuous system design. Alignment of this technology for future NASA (Artemis) and commercial missions (Xelene) is critical for future integration and with the help of our team, we will assess system robustness metrics required for Phase IIE/III. In Phase II we will build the semi-continuous extraction system that can process 7kg/hr of icy lunar simulant and optimize the process parameters based on the input from NASA and our commercial partners.

Ionic Liquid-Assisted Electrochemical Extraction of Metals and Oxygen from Lunar Regolith, 2022 SBIR Phase I

In Phase I, Faraday and RoCo will optimize the ionic liquid to rapidly digest metal silicates like feldspar. Next, Faraday will demonstrate and optimize the electrochemical recovery of metals and oxygen from the ionic liquid containing the digested metals and water. Finally, the electrochemical process will be used to regenerate the ionic liquid for digestion of additional metal silicates.

Ionic Liquid-Assisted Electrochemical Extraction of Oxygen from Lunar Regolith, 2020 SBIR Phase I

Among the numerous technological advances sought in order to facilitate human exploration and habitation on Moon, solutions and innovations are needed for processing local resources to support sustainable and long duration space missions. Such in-situ resource utilization (ISRU) is aimed at reducing the payload mass during launch and eliminate the need for ground support for long-term missions and ultimately space colonization. One particular need for habitation and deep space exploration is the continuous supply of oxygen for life support and for propellants in the form of liquid oxygen. As missions are foreseen to extend with limited accessibility of earth resupply, the availability of oxygen will become critical. Electrochemical methods coupled with ionic liquids offer low-temperature, scalable solutions for oxygen extraction at large scales.

In Phase I, Faraday and Liquid Ion Solutions will design and investigate an ionic liquid-assisted electrochemical process capable of recovering oxygen from lunar regolith. A task specific ionic liquid for the solubilization of minerals and metals found in lunar regolith will be developed, and followed by an electrochemical liquid-liquid-solid process utilizing engineered electric fields, for oxygen recovery with simultaneous silicon electrodeposition as a potentially useful byproduct. Toward the end of Phase I, the project team will estimate the scalability and performance expectation of the proposed design and evaluate its potential to achieve the 1.85 kg O2/hr target within the NASA solicitation. Phase II will develop, design, and fabricate a sub-scale lunar regolith oxygen extraction system. These efforts will enable further understanding of the processing parameters requirements and promote new commercial relationships within Phase III. This technique will also enable substantial development in metal recovery, recycling, and refining industries, and will be an integral part of successful mission development within NASA.

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