Article: The proof is in the plastic: three-dimensional printing technology translated scans of the space shuttle tiles for safety evaluation. The same technology allows proof of concept before metal is machined.(MEASUREMENT/INSPECTION)

Just after lift-off, August 13, 2007, Space Shuttle Endeavour's Thermal Protection System-TPS--suffered damage due to a strike by foam insulation falling from the shuttle's external fuel tank. Sensors detected damage to the heat-resistant tiles lining the orbiter's underbelly, posing a threat to the shuttle's safe re-entry to Earth.

The TPS consists of thousands of heat-resistant silica-based tiles that keep the heat from atmospheric re-entry from being transferred to the shuttle's aluminum structure. However, the tiles are relatively delicate and are easily damaged. Insulating foam shed from the external fuel tank due to aerodynamic forces can damage the tiles.

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