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Selective Laser Melting of a 1U CubeSat Structure. Design for Additive Manufacturing and Assembly

机译:1U立方体结构的选择性激光熔化。添加剂制造和装配设计

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The aerospace industry has used Additive Manufacturing (AM) since its beginnings in the '80s. But in the last decade, new advancements in these technologies have led applications to proliferate moving from the prototyping to the direct part manufacturing, rapid tooling, and repairing. AM is a completely new manufacturing process if compared to the conventional subtracting methods. This technology has deeply influenced product design and assembly in the aerospace sector, becoming a strategic technology throughout the entire supply chain. AM enables easy integration of design change. It has the capability to build virtually any shape, and at least as importantly it allows complex features integration and part count reduction, greatly simplifying the product final assembly. These advantages can be addressed to the production of small satellites constellations, made by up to some hundreds of satellites, finding an optimum compromise between customization and modularization needs. The present work shows a re-design of the structural sub-system of a CubeSat from the nanosatellite class. Specifically, a 1U CubeSat design has been developed taking into account the consolidation of parts, integrating the features into more complex elements, reducing and/or avoiding the assembly issues, ignoring the constraints imposed by conventional processes while considering AM built related factors. A new 1U CubeSat composed of two already-assembled parts has been fabricated by the Selective Laser Melting (SLM) technology. Particular care has been taken for new features, e.g. the clearance and the shape of the hinge and the snap joint matching SLM specific constraints such as support structures design and removal planning, part orientation in the building platform, and hollowing out for powder removal. The obtained results point out AM as a key technology allowing for a drastic reduction of the part count for a complex mechanical system, as a small satellite structure is. Nevertheless, t
机译:自上世纪80年代开始在航空航天工业已经使用的添加剂制造(AM)。但在过去的十年中,这些技术新的进步已经导致从原型移动到直接零件制造,快速模具和修复应用增殖。 AM是如果相比于传统减法方法一个完全新的制造工艺。该技术已深深影响了在航空航天领域产品的设计和组装,成为一个战略性的技术在整个供应链。 AM能够轻松集成设计变更。它建立几乎任何形状的能力,至少同样重要的是它可以让复杂的功能整合和零件数量减少,大大简化了产品的最终组装。这些优势可以给生产小卫星星座,高达做出几百卫星,发现定制,模块化的需求之间的最佳平衡。目前的工作示出了从超小型卫星类立方体卫星的结构子系统的重新设计。具体而言,1U的CubeSat设计已被开发考虑到部件的合并,这些特征整合到更复杂的元素,减少和/或避免了装配问题,忽略同时考虑AM内置相关因素通过常规方法施加的约束。的两个已装配的部件组成的新的立方体卫星1U已经通过选择性激光熔化(SLM)技术制造的。特别护理已采取新的功能,例如电气间隙和铰链的形状和咬合连接匹配SLM具体的限制,例如支持结构设计和拆除规划,建造平台部分方向,并挖空粉末去除。将得到的结果指出AM作为关键技术允许用于复杂机械系统的显着降低的部分计数,作为一个小的卫星结构。尽管如此,T

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