13.04.2021

NeoSAT Phase C

Additive Manufacturing of a Metallic Structural Component for Satellites First, the existing design was reviewed and optimization potential identified to derive the monolithic design concept for 3D printing. All manufacturing-relevant aspects, such as manufacturing tolerances, clamping concept, etc., were considered in this phase. After verification by the customer, a total of 12 components were additively manufactured and prepared for the test campaign. Finally, static and dynamic load tests and geometric measurements were carried out as part of quality assurance. The Technology Readiness Level (TRL) was raised to 6 out of a maximum of 9.

FOTEC Forschungs- und Technologietransfer GmbH

Background

This structural component is a mounting bracket for solar panel actuators, part of the NeoSAT platform. The conventionally manufactured assembly consists of five individual parts (milled and bent sheet metal components). The aim is to evaluate the use of additive manufacturing (3D printing) and test it using functional prototypes to save weight and minimize assembly and storage costs. It is essential that the 3D-printed version also passes all required tests for component qualification in the aerospace industry. The 3D-printed version must also pass all necessary tests for component qualification in the aerospace industry.

Objectives

Weight reduction of at least 10% compared to the conventional version
Mechanical strength meets specification requirements
Reduction of individual parts (ideally from 5 to 1)
Continuous quality control and documentation
Verification of reproducibility

Milestones

MRR - Manufacturing Readiness Review

Completion of component manufacturing and start of preparation for the testing phase

TRR - Test Readiness Review

Completion of all necessary preparations for the testing phase

FR - Final Review

Project completion

Results

Successful production of functional prototypes from aluminum
Achieved weight reduction of 21.4%
Mechanical strength meets customer requirements
Economic analysis conducted
Monolithic design (only one component, resulting in reduced assembly costs)

Further information