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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 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：由于其独特的能力，航空航天工业自80年代的开头以来使用了添加剂制造业（AM）。本工作显示了从纳米卫星类别的立方体的结构子系统的重新设计和制造。具体而言，考虑到零件的整合来减少和/或避免装配问题，已经开发了1U CubeSat设计提案。仅通过选择性激光熔化（SLM）技术成功制造了仅由两部分制成的配置。 AM功能允许在设计中集成铰链机制，使得产生的结构已经组装了一个。此外，该设计展示了搭扣配合特征，以摆脱紧固件。由于额外的快置特征的集成，部件的复杂性增加导致由于AM能够管理形状复杂性而导致的制造问题。这项工作点作为一个关键技术，允许削减机械系统的零件数量急剧减少，使装配（DFA）指南设计为极端。它强调需要考虑与设计阶段中的am相关的约束，例如铰链的间隙和形状以及搭扣匹配的SLM特定约束，例如支持结构设计和拆卸计划，建筑平台中的部分方向，并挖空粉末去除。

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