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As part of the Design for Additive Manufacturing course (AMD/EDSGN 562) at Penn State, led by Timothy W. Simpson and TA Jayant Mathur, my team and I tackled the Pixy Stix Return (PSR) Challenge, inspired by NASA's groundbreaking Mars Sample Return Mission 🌌. Background: The Mars Sample Return Mission 🌕 aims to bring rock samples from the Martian surface back to Earth 🌍, using advanced engineering to design robust orbiting containers 🛰️ and safe re-entry mechanisms. Inspired by this, our challenge was to create a container capable of holding and protecting 30 Pixy Stix 🍬 during extreme freefall conditions ⏬ while ensuring strength, light weight, and functional efficiency. Our Team Solution: 🛠️ Components: Base container, lid, spacer, and propeller 🔗 Integrated body-centered cubic lattice structure for strength and weight optimization with gradient density Challenge Requirements ✅: • Securely hold 30 Pixy Stix 🍭 (134 mm height, 5–6 mm diameter) • Weigh ≤ 500 g ⚖️ • Survive a 100-ft freefall onto concrete 💥 without parachutes 🪂 • Prevent deformation and ensure no contents escape or enter 🛡️ • Built within 127x127x254 mm 📐 dimensions using Metal Laser Powder Bed Fusion (LPBF) with materials like AlSi10Mg, 316L Stainless Steel, Ti6Al4V, or Inconel 718. Our project reflects how additive manufacturing can address real-world challenges inspired by space exploration, pushing boundaries in design and engineering. 👥 Team Members: Ali Alhussain, Christian Richter, Ethan Gross, Shreyas Nagaraj, Tyler Boyle, and Zulfiqar Islahqamat. 📚 Learn More About the Context: Mars Sample Return Mission: • Mars Sample Return: Bringing Mars Rock Sam... Perseverance Backup Rock Tubes: • Perseverance’s Backup Rock Sample Tubes Pl... Mars Return Concept Animation: • Mars Sample Return Conceptual Animation Mars Sample Return Orbiting Sample Container Concept Model: https://science.nasa.gov/resource/mar... Inspiration: https://pin.it/3TtkGv18N 🚀✨ Watch how we brought this challenge to life—from design to testing—using additive manufacturing processes and technologies! #PixyStixReturn #AdditiveManufacturing #MarsSampleReturn #PSRChallenge #3DPrinting #EDSGN562 #AMD562 #PennState #MetalLPBF #EngineeringDesign #SchoolofEngineeringDesignandInnovation #TheLearningFactory #LearningFactoryPennState #NASAInspired #Innovation #MarsMission #StudentEngineering #DfAM #MfAM #DesignForAM #SpaceEngineering #3DPrintedSolutions #STEM #MarsExploration #InspiringInnovation