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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Industry partners of the DMRC Show image information
Industry partners of the DMRC Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites Show image information
Employees of the DMRC working with the "freeformer" from Arburg Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM) Show image information
Powder particles are used as raw material for laser-based additive manufacturing Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Industry partners of the DMRC

Industry partners of the DMRC

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part

Additive manufactured reaction wheel bracket for telecomunication satellites

Employees of the DMRC working with the "freeformer" from Arburg

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM)

Powder particles are used as raw material for laser-based additive manufacturing

AM for satellites: Reaction Wheel Bracket

Objectives
Main aim of the study was to determine whether direct manufacturing of structure elements for satellites is feasible. High complex mission-customized parts with a high buy-to-fly ratio had to be examined to show the potential for reducing weight, waste, cost and time during production and use.

Traditional design of Reaction Wheel Bracket mounted in Exo Mars satellite

Procedure
After a profound analysis of many satellite parts a huge bracket was chosen. It is used four times per satellite for holding a mechanism where a mass is set into rotation to use the moment of inertia for adjusting satellites orientation in space without using propellant. As a computer-aided geometry creation topology optimization was used in a multi-step optimization procedure. For the retransition of calculation results a voxel-based approach is used to cover the high complex geometries with biologic seeming shapes.

AM Designed Reaction Wheel Bracket

Achievements
During the study a new highly time efficient semiautomatic voxel-based methodology for geometry retransition of topology optimization results was found. This enables a fast and stress optimal design. Furthermore the product related key figures show the remarkable potential of additive manufacturing for huge structural parts, even with regard to costs:

  • Weight reduction: - 60 % (1100g -> 450g)
  • Waste reduction: - 98 % (56kg -> 0.8kg)
  • Cost reduction: - 53 % (8000€ -> 3800€)
  • Time reduction: - 32 % (59h -> 40h)
  • Max. Displacement: - 37 %
  • 1st Eigen frequency: + 20 %
AM Designed Reaction Wheel Bracket
ESA

The Reaction Wheel Bracket was used as a sample part in the Project NewStructure, funded by the European Space Agency (ESA).

Contact

Prof. Dr. Rainer Koch

Computeranwendung und Integration in Konstruktion und Planung

Rainer Koch
Phone:
+49 5251 60-2258
Fax:
+49 5251 60-3482
Office:
P1.3.19

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