3D Printing & Optimized Design are Pushing Space Systems Further

3D Printing is having a huge impact on space systems design and new component prove that fact.

Altair announced today that RUAG Space, with the support of Altair ProductDesign, has built a redesigned, optimized antenna support for an Earth observation satellite, to be produced using industrial additive manufacturing, or 3D printing. The objective was to create an aluminum component that would be significantly stiffer while at the same time lighter, taking full advantage of the design freedom afforded by 3D printing.

To redesign and optimize the antenna, engineers used Altair HyperWorks® solver OptiStruct®, guaranteeing a load-sufficient material distribution. For the design, engineers used solidThinking Evolve®. Design freeze was reached after only four weeks. The component was then manufactured with a 3D printer, with no need of further design adjustments. Using topology optimization in conjunction with additive manufacturing, the team achieved elite weight and stiffness performance characteristics not possible using conventional analysis and manufacturing techniques.

EOS, the German market leader in the area of industrial 3D printing, contributed its additive manufacturing expertise, handling the manufacturing of the aluminum components. Weight reduction is a decisive factor in the space industry since the lighter a satellite is, the less it costs to launch. Some 40 centimeters long, the antenna support is one of the longest metal components ever produced using the powder bed manufacturing method. To check that the new support is ready for use in space, it is currently undergoing a battery of intensive qualification tests that are scheduled to be completed by the end of the year.

“Our goal is to equip one of the future Sentinel-1 satellites with antenna support components that have been manufactured using an industrial 3D printer,” explained Michael Pavloff, Chief Technical Officer at RUAG Space. He went on to add that the production of this antenna support was by no means a one-off. “3D printing has enormous potential for our business, and we are currently in the process of developing further space applications. In the future it will be possible to create entire satellite structures using a 3D printer. This means that electrical harnesses, reflectors, heating pipes, and other assemblies that today still have to be manufactured individually could then be integrated directly into the structural elements,” Pavloff concludes.

“At Altair we were delighted to contribute to such a significant milestone in satellite design. The collaboration with RUAG Space and EOS allowed us to deliver even more innovative end-to-end design and optimization processes to exploit the benefits of additive manufacturing,” said Pietro Cervellera, Managing Director Altair GmbH.

Source: Altair