Abstract
Three case studies utilizing topology optimization and Additive Manufacturing for the development of space flight hardware are described. The Additive Manufacturing (AM) modality that was used in this work is powder bed laser based fusion. The case studies correspond to the redesign and manufacture of two heritage parts for a Surrey Satellite Technology LTD (SSTL) Technology Demonstrator Space Mission that are currently functioning in orbit (case studies 1 and 2), and a system of five components for the SpaceIL’s lunar launch vehicle planned for launch in the near future (case study 3). In each case, the nominal or heritage part has undergone topology optimization, incorporating the AM manufacturing constraints that include: minimization of support structures, ability to remove unsintered powder, and minimization of heat transfer jumps that will cause artifact warpage. To this end the topology optimization exercise must be coupled to the Additive Manufacturing build direction, and steps are incorporated to integrate the AM constraints. After design verification by successfully passing a Finite Element Analysis routine, the components have been fabricated and the AM artifacts and in-process testing coupons have undergone verification and qualification testing in order to deliver structural components that are suitable for their respective missions.
Highlights
Additive Manufacturing, or AM, is the potentially disruptive manufacturing technology in which a structural component is fabricated layer by layer via digital information
This paper discusses the design for Additive Manufacturing of light-weight, topologically optimized components that are intended for spaceflight, and will focus on three illustrative examples: Designs 2018, 2, 51; doi:10.3390/designs2040051
Manufacturing considerations, such as the minimization of overhangs, encapsulated powder, and heat accumulation are not included in the topology optimization formulations that are presented in this work, a subsequent Finite Element Modeling is necessary because the aforementioned considerations are incorporated manually in the topology optimization routine with significant ‘human-in-the-loop’
Summary
Additive Manufacturing, or AM, is the potentially disruptive manufacturing technology in which a structural component is fabricated layer by layer via digital information. Manufacturing’ has evolved to generally describe the technologies, such as Solid Freeform Fabrication, which strives to build functional components layer-by-layer from digital information, and includes powder bed fusion processes, wire deposition, and directed energy deposition [6]. The laser beam scans the new layer with information corresponding to the new geometrical slice and the process is repeated until the three-dimensional (3D) component is fabricated and contained within the lowered powder bed.
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