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Selective Laser Melting of a 1U CubeSat structure. Design for Additive Manufacturing and assembly

机译：1U CubeSat结构的选择性激光熔化。增材制造和组装设计

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The aerospace industry has used Additive Manufacturing (AM) since its beginnings in the '80s because of its unique capabilities. The present work shows a re-designing and the manufacturing via AM of the structural subsystem of a CubeSat from the nanosatellite class. Specifically, a 1U CubeSat design proposal has been developed according to Design for Additive Manufacturing (DFAM) guidelines, considering the consolidation of the parts for reducing and/or avoiding the assembly issues. A configuration made of only two parts has been successfully fabricated via Selective Laser Melting (SLM) technology. AM capabilities allowed to integrate a hinge mechanism in the design, making the resulting structure an already-assembled one. Moreover, the design exhibits snap-fit features in order to get rid of fasteners. The increased complexity of the parts due to the integration of the additional snap-fit features results in no manufacturing issues due to the AM capability to manage shape complexity. This work points AM out as a key technology allowing for a drastic reduction of the part count for a mechanical system, taking Design for Assembly (DFA) guidelines to the extreme. It underlines the need to consider AM-related constrains already in the design phase, such as 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.
机译：自80年代以来，航空航天业就一直使用增材制造（AM），因为它具有独特的功能。本工作显示了纳米卫星类CubeSat的结构子系统的AM重新设计和制造。具体而言，根据增材制造设计（DFAM）指南，已开发出1U CubeSat设计方案，其中考虑了零件合并以减少和/或避免组装问题。通过选择性激光熔化（SLM）技术成功地制造了仅由两部分组成的配置。 AM功能允许在设计中集成铰链机制，从而使最终结构成为已经组装好的结构。此外，该设计还具有卡扣配合功能，以消除紧固件。由于集成了额外的卡扣配合功能，零件的复杂性增加了，而由于AM具有管理形状复杂性的能力，因此没有制造问题。这项工作指出了AM是一项关键技术，可以极大地减少机械系统的零件数量，从而最大限度地提高了装配设计（DFA）准则。它强调需要在设计阶段就考虑与增材制造相关的约束，例如铰链的间隙和形状以及与SLM特定约束相匹配的按扣，例如支撑结构设计和拆卸计划，建筑平台中的零件方向，然后掏空去粉。

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