Novel structural components for launchers/satellites applications using additive manufacturing technologies
Programme
GSTP
Programme Reference
GT1A-004MS
Prime Contractor
FUNDACI?N ANDALUZA PARA EL DESARROL AEROESPACIAL
Start Date
End Date
Status
Closed
Country
Spain
Objectives
The objective of this activity is the development of AM-SLM laser melting processes for launchers/satellites fittings and antennas, and the manufacturing of advanced complex shape ceramics parts with Binder Jetting technology for heat pipes wicks and electronic packaging in Al-SiC
Description
Additive manufacturing technologies are emerging as a process to machining for small series, complex and costly parts allowing reduction in cost and time. The combination of issues (fabrication of unique products, short series, need for weight reduction through topology optimization) makes AM processes attractive for developing a large family of metallic parts for launcher and satellite applications. Space-flight hardware design involves complex geometries that can be produced by AM. The use of AM can be an important step to evolve work procedures, redesigning parts or assemblies faster with mass savings, reducing manufacturing costs and time. ;The scope of the activity is to improve the maturity of SLM laser melting processes and Binder Jetting. ;;
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The SLM activity focuses on the development of AM-SLM laser melting processes for launchers/satellites fittings and antennas with the aim of reducing lead-time amp; cost, increasing flexibility and functionality and fully qualifying this AM process for a space product. The binder jetting additive manufacturing consists of a powder bed process in which the powder is fed layer by layer. Unlike in other powder bed processes, the binder jetting does not use any heat source to join the powder particles but uses an organic binder. Once the process has been completed a complex shape ?green body? is obtained. Then this green body is subjected to a de-binding step and a subsequent sintering step to consolidate the material. The Binder Jetting activity focuses on:
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- improving Binder Jetting technology for ceramic part manufacturing
- increasing shape complexity of the electronic packaging components
- simplifying complex shape part manufacturing process
- decreasing lead-time and cost of complex shaped ceramic parts. ;
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The following tasks are to be performed:
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- Identification of launcher and satellite components, antennas and complex shape SiC parts available for AM manufacturing with end-user specifications
- Redesign of components (topology optimization for SLM) for AM
- Component manufacturing and qualification with SLM and BJ processes under launcher/satellite specifications
- Inspection system set up and adapting standards for process qualification
Definition of quality procedures for acceptance of components
Application Domain
Generic Technologies
Technology Domain
24 - Materials and Manufacturing Processes
Competence Domain
2-Structures, Mechanisms, Materials, Thermal
Keywords
38-Advanced Manufacturing
Initial TRL
TRL 4
Target TRL
TRL 6
Achieved TRL
TRL 8