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ADDITIVE LAYER MANUFACTURING FOR ENTRY CAPSULES

机译：进入胶囊的附加层制造

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CIRA is designing and realizing the structures, mechanisms and Thermal Protection System (TPS) of a capsule conceived for the demise observation of upper stages of various launch vehicles. The purpose of the project is to produce a completely autonomous capsule able to sustain re-entry, and devoted to the study and observe the demise of launch vehicle stages. The analysis of the re-entry data on objects re-entering the atmosphere will help in accurately predicting break-up altitudes, debris trajectories and ground impact footprints. These analyses are therefore critical not only for mission success, but more importantly for improving public safety aspects of such re-entry scenarios. The capsule will be connected to the same launcher stage it will monitor and observe during the re-entry. Once in orbit, the capsule will wake-up and will perform its measurements and observations. It will remain connected to the launcher stage during the first part of the re-entry, but it will decide to disconnect from launcher when its host starts to disintegrate. In a fall towards the Earth, it will continue making measurements and at the same time relay its measurement data to ground. The capsule must be constructed such that it will be able to withstand the hostile conditions of the launch, the re-entry and close-by disintegration of the launcher. The project is halfway its duration. For the program an Engineering Qualification Model (EQM) shall be produced as well as a Proto-Flight Model (PFM). Because the tight schedule, the small size of the capsule, about 30 cm in diameter, and the small number of items to be produced for this particular mission, CIRA has selected a rapid prototyping system for the manufacturing of the EQM and PFM. In particular, the structural parts of the PFM shall be made by Titanium alloy using the Electron Beam Manufacturing (EBM) capabilities owned by CIRA. This technique permits to generate very complex shapes at the same cost of simple shapes. This permits the designer to achieve higher shape and structural efficiency. The paper shows how the peculiarities of the ABM are exploited and how the "think-additive" approach is interpreted for this manufacturing case. In particular, the paper describes some of the design solutions aimed to minimize the need of post fabrication machining. The capsule main structure is made by two pieces that are bolted together.
机译：CIRA正在设计和实现一种胶囊的结构，机制和热保护系统（TPS），该胶囊旨在对各种运载火箭的上半部进行消亡观察。该项目的目的是生产一个能够维持重返太空的完全自主的太空舱，并致力于研究并观察运载火箭阶段的消亡。对物体重新进入大气层的再入数据的分析将有助于准确预测破碎高度，碎片轨迹和地面撞击足迹。因此，这些分析不仅对于成功完成任务至关重要，而且对于改善此类重入场景的公共安全方面也至关重要。太空舱将连接到在重新进入期间将进行监视和观察的同一发射器阶段。一旦进入轨道，太空舱将醒来并执行其测量和观察。在重新进入的第一部分期间，它将保持与发射器阶段的连接，但是当其主机开始分解时，它将决定与发射器断开连接。在向地球坠落时，它将继续进行测量，同时将其测量数据中继到地面。胶囊的构造必须使其能够承受发射器的恶劣条件，发射器的重新进入和近距离解体。该项目是其持续时间的一半。对于该程序，应生成工程资格模型（EQM）以及原型飞行模型（PFM）。由于时间紧，胶囊尺寸小，直径约30厘米，要为该特定任务生产的物品少，因此CIRA选择了一种快速成型系统来制造EQM和PFM。特别是，PFM的结构部件应使用CIRA拥有的电子束制造（EBM）功能由钛合金制成。该技术允许以简单形状的相同成本生成非常复杂的形状。这允许设计者获得更高的形状和结构效率。本文说明了如何利用ABM的特殊性以及如何针对这种制造情况来解释“思维加法”方法。特别是，本文描述了一些旨在最大程度减少后期加工需求的设计解决方案。胶囊的主要结构是由两块螺栓连接在一起制成的。

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