1. Motivations, Opportunities and
Challenges of Additive Manufacturing
for Space Application
Franck Mouriaux
General Manager Structures
RUAG Schweiz AG
RUAG Space
Dearborn, Mai 6th 2015

2. manf’
flexibility
for free
design
complexity
for free
design
MASS
reduction
lead
TIME
reduction
function
integration
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Why
AM?
FREEDOM

3. SUPPLIER
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PRODUCT
post-
processing verification
How
AM?
qualification
design analysis
PROCESS MATERIAL

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Where
AM?
EVERY
WHERE

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SENTINEL-1

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Original Design
1.6kg
88.7Hz
163MPa
2
First Optimisation Loop
1.2kg
88.7Hz
1
SENTINEL-1 Antenna Support Bracket

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Original design
enveloppe
Original
interfaces
Original
loading
Original
electrical
grounding
SENTINEL-1 Antenna Support Bracket

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Original design
enveloppe
Original
interfaces
Original
loading
Original
electrical
grounding
SENTINEL-1 Antenna Support Bracket

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3
Final Design
0.936kg
91.5Hz
103MPa
SENTINEL-1 Antenna Support Bracket

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Topology Optimization
Topology Loadpath
CAD interpretation
Baseline CAD Design space
Load Cases
Optimisation loops
Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
Detailed
Verif.
Additive
Manf’

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• Understand where to start
• Definition of design space
• Definition of load cases
• Definition of material
Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
Stress
Verif.
Additive
Manf’

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Optimization problem formulation:
• Objective: Minimize Mass OR Compliance
• Constrains: Vol. frac. / Stress / Freq / Manf’
• Variables: Element densities
Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
Stress
Verif.
Additive
Manf’

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Model
Preparation
Concept
Optimis.
Concept
Interpret.
4 5 6 7
• Obtained topology must be realized into a
proper CAD design
• Understand and apply design principles
from AM
• Printing orientation
• Overhang angle consideration
• Heat dissipation and stress concentration
• Post-processing consideration
• Understand results from optimization
• Observe similarities
• Identify primary and secondary load paths?
• Cross sections geometries depending on
structural behaviour

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Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
5 6 7
Loadpath from topology iterations interpretated as CAD model
with Solidthinking® Evolve.

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Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
6 7
Shear web could be replaced
with cross members
Cross member could be
discarded
• Many sections highlighted proved to be redundant after
incorporating mounting interfaces.
• Findings from Loop2 topology iterations implemented in the
new CAD

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Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
Detailed
Verif.
7
Dynamic Verification
Static Strength Verification

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Model
Preparation
Concept
Optimis.
Concept
Interpret.
Concept
Design
Detailed
Optimis.
Detailed
Verif.
Additive
Manf’
The parts printed from an EOS M400 from the company CITIM.
Material: AlSi10Mg
(AA357-AA359 casting alloy)

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 Geometrical verification
 Modal verification
 Quasi-static load test
 Sine vibration tests (3-dir.)
 Random vibration tests (3-dir.)
 Vibration Test
 Geometrical verification
 Modal verification
 Quasi-static load test
Qualification Flight
Model Philosophy

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Comparison of QM geometry with CAD model and identification of
deviation.
Computer tomography scan with resolution of 320m
Verification

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Test specimens were printed within the same print job as the two S1 AM
brackets.
Verification

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In-plane (XZ) low level sine sweep to verify the frequency requirement.
Frequency search spectrum
Frequency [Hz] Amplitude [g] Speed [oct/min] direction
5 to 2000 0.2 2 One sweep up
TEST RESULTS Predicted Measured
1st Eigen frequency (X) 90.0 Hz 91.4 Hz
2nd Eigen frequency (Z) 106.9 Hz 109.0 Hz -X
Z
X-response Z-response
Verification

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Out-of-plane (Y) low level sine sweep to verify the frequency requirement.
Y
TEST RESULTS Predicted Measured
1st Eigen frequency 106.9 Hz 107.8 Hz
Verification

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SG08: 282
SG09: 246
Strength verification under static, sine and random loading.
Qualification

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Qualification

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Topology
Optimisation
Design / Optimisation Manufacturing Verification / Testing
 Functional analysis
 Topology optimisation
 CAD Interpretation
 Size/Shape Optimisation
 Detail Stressing
 Optimisation
 Post-Processing
 Samples Definition
 Process Control
 Quality Control
 Test Definition
 Qualification Testing
 Model Correlation
CAD
Interpretation
Manufacturing Verification Testing
Additive Manufacturing Development Process

26. Main Challenges…
 Acceptance of the technology by customers and authorities
 Qualification and control of the materials and processes
 Development of additive manufacturing technologies
 Development of new engineering thinking
 Development of new design tools
 Acceptance
 Qualification
 Development
 Development
 Development
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27. AM in Space…more than a hype!
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"My goal is to have over 50% of the structures 3-D-
printed within two to three years,"
Richard Ambrose, executive vice president of
Denver-based Lockheed Martin Space
Systems
Jul 24, 2014
Lockheed Martin Testing 3-D-Printed Subsystems On A2100 Space Bus | AWIN
ONLY content from Aviation Week
Lockheed Martin Testing 3-D-Printed Subsystems On A2100
Space Bus

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Advanced Spacecraft Structures
3D-printed LVA Ring
Large dimensions parts
3D-printed LVA Ring
Large dimensions parts
Full integration of metal to
composite
Full integration of metal to
composite
3D-printed isogrid
central tube with
integrated interfaces
3D-printed isogrid
central tube with
integrated interfaces

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Advanced Spacecraft Structures
Integrated high power 3D-
printed heatpipes
Integrated high power 3D-
printed heatpipes
Integrated metal coated
plastic 3D-printed wave-
guides
Integrated metal coated
plastic 3D-printed wave-
guides
Surface printed
electrical circuits
Surface printed
electrical circuits
Thermo-optical
surface coating
Thermo-optical
surface coating

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Advanced Spacecraft Structures
Lightweight 3D-printed
brackets with adaptive
stiffness and damping
Lightweight 3D-printed
brackets with adaptive
stiffness and damping
Thin plies CFRP sandwich
with ultralight 3D-printed
core with anti-telegrahing
feature
Thin plies CFRP sandwich
with ultralight 3D-printed
core with anti-telegrahing
feature
High efficiency 3D-printed
solar cells
High efficiency 3D-printed
solar cells

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Advanced Spacecraft Structures

32. Thank you for your attention!
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Franck Mouriaux
General Manager Structures
RUAG Schweiz AG
RUAG Space
Schaffhauserstrasse 580
8052 Zürich · Switzerland
Tel. +41 44 306 21 37
Fax. +41 44 306 27 50
Mobile: +41 78 709 56 71
franck.mouriaux@ruag.com
http://www.ruag.com