OHB System AG and the Fraunhofer Research Institution for Additive Manufacturing Technologies (IAPT) have developed a standardized additive manufacturing process chain for space components. The project, commissioned by the European Space Agency, focused on establishing design and manufacturing guidelines for producing spacecraft components using powder bed fusion laser beam metal (PBF-LB/M) technology. The partners validated their approach by optimizing three satellite components through this manufacturing route.
The implementation of additive manufacturing in space applications faces unique challenges related to industry-specific quality and safety standards. To address these requirements, the project team created comprehensive design, manufacturing, and validation rules specifically tailored to space industry needs. Their work included knowledge transfers, material investigations, and supplier benchmarks to ensure compliance with necessary standards.
The process was tested on three increasingly complex spacecraft components: a connector element with controlled stiffness properties, a reaction wheel bracket with embedded click nuts, and an integrated twin mirror. According to the results, the additively manufactured components achieved weight reductions of up to 45 percent. The twin mirror, the most complex component, demonstrated lower thermal deformation and improved optical properties due to optimized mounting points.
Dr. Marco Mulser, Head of Technology Coordination at OHB System AG, stated, “With the help of Fraunhofer IAPT, OHB was able to establish a reliable process chain that now allows us to use high-quality AM components for our satellite projects.” The collaboration has established design and verification competencies along with a reliable supply chain for titanium and aluminum components.
The additive manufacturing process offers several advantages for satellite applications beyond weight reduction. These benefits include functional integration, reduced assembly effort, and shorter development times. The project demonstrates how PBF-LB/M technology can be effectively implemented in industries with strict quality and safety requirements.
Additional information about the “Additive Manufacturing Maturation” project (GSTP 4000125275/18/NL/AR/zk) is available on the Fraunhofer IAPT website, including a freely accessible white paper detailing the project approach and components.
Source: idw-online.de