Case Study: NASA achieves durable rover prototyping for extreme Mars-like conditions with Stratasys FDM 3D printing

NASA uses Stratasys FDM parts to survive thousands of miles per hour launch stresses

The customer, NASA, faced the challenge of designing a human-supporting rover for Mars that had to be extremely lightweight yet strong enough to withstand intense launch vibrations and the harsh conditions of space. Their mantra, "failure is not an option," required them to find a way to validate designs without committing to expensive tooling. To overcome this, they utilized FDM 3D printing technology from the vendor, Stratasys.

Stratasys provided a solution where NASA engineers could 3D print prototypes to test the form, fit, and function of parts before final manufacturing. This process allowed NASA to solve design challenges early, ensuring machined parts were based on the best possible design while staying within budget. The result was the successful integration of Stratasys FDM-printed parts into the rover used in the Desert Research and Technology Studies program, helping NASA bridge the gap between practical manufacturability concerns and the drive for discovery.

NASA