Additive Manufacturing for Lightweighting Satellite Platform

Boschetto, Alberto; Bottini, Luana; Macera, Luciano; Vatanparast, Somayeh

doi:10.3390/app13052809

Cited by 13 publications

(4 citation statements)

References 57 publications

(63 reference statements)

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“…AM techniques have been effectively employed in the space sector for nearly two decades. In this sense, AM techniques for the fabrication of spacecraft parts and satellite structures have been successfully used by scholars [466][467][468][469][470][471][472] and space contractors [473,474]. AM technology has also been used to manufacture functional engines suitable for small spacecraft [475,476].…”

Section: Additive Manufacture Applied To the Satellite Industrymentioning

confidence: 99%

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2023

Aerospace

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Launching satellites into the Earth’s orbit is a critical area of research, and very demanding satellite services increase exponentially as modern society takes shape. At the same time, the costs of developing and launching satellite missions with shorter development times increase the requirements of novel approaches in the several engineering areas required to build, test, launch, and operate satellites in the Earth’s orbit, as well as in orbits around other celestial bodies. One area with the potential to save launching costs is that of the structural integrity of satellites, particularly in the launching phase where the largest vibrations due to the rocket motion and subsequent stresses could impact the survival ability of the satellite. To address this problem, two important areas of engineering join together to provide novel, complete, and competitive solutions: topology optimisation methods and additive manufacturing. On one side, topology optimisation methods are mathematical methods that allow iteratively optimising structures (usually by decreasing mass) while improving some structural properties depending on the application (load capacity, for instance), through the maximisation or minimisation of a uni- or multi-objective function and multiple types of algorithms. This area has been widely active in general for the last 30 years and has two main core types of algorithms: continuum methods that modify continuous parameters such as density, and discrete methods that work by adding and deleting material elements in a meshing context. On the other side, additive manufacturing techniques are more recent manufacturing processes aimed at revolutionising manufacturing and supply chains. The main exponents of additive manufacturing are Selective Laser Melting (SLM) (3D printing) as well as Electron Beam Melting (EBM). Recent trends show that topology-optimised structures built with novel materials through additive manufacturing processes may provide cheaper state-of-the-art structures that are fully optimised to better perform in the outer-space environment, particularly as part of the structure subsystem of novel satellite systems. This work aims to present an extended review of the main methods of structural topology optimisation as well as additive manufacture in the aerospace field, with a particular focus on satellite structures, which may set the arena for the development of future satellite structures in the next five to ten years.

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Section: Additive Manufacture Applied To the Satellite Industrymentioning

confidence: 99%

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2023

Aerospace

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“…To reduce the stress concentration and provide a more lightweight core design, the lattice core can be graded through the thickness. Zhang et al [29] and Boschetto et al [30] already used additively manufactured graded lattice cores to avoid stress concentrations and enhance the dynamic behavior in satellite housings. Costly and time-consuming finite element analyses are used for the design of such lattice cores, as lattice cores are poorly studied by analytical approaches [31,32].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Performance Comparison of Sandwich Panels with Graded Lattice and Honeycomb Cores

Georges,

García Solera,

Aguilar Borasteros

et al. 2024

Biomimetics

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The design of graded and multifunctional lattice cores is driven by the increasing demand for high-performance components in lightweight engineering. This trend benefits from significant achievements in additive manufacturing, where the lattice core and the face sheets are fabricated simultaneously in a single print job. This work systematically compares the mechanical performance of sandwich panels comprising various graded lattice cores subjected to concentrated loads. In addition to graded lattice cores, uniform lattices and conventional honeycomb cores are analyzed. To obtain an optimized graded lattice core, a fully stressed design method is applied. Stresses and displacements are determined using a linear elastic analytical model that allows grading the core properties in a layerwise manner through the core thickness. The analysis indicates the superior performance of graded lattice cores compared to homogeneous lattice cores. However, conventional honeycombs outperform graded lattice cores in terms of load-to-weight ratio and stiffness-to-weight ratio. This study provides valuable insights for the design of lattice core sandwich panels and the advantages of several design approaches.

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“…The outstanding energy absorption capabilities of lattice structures are implemented in blast-resistive structures [ 43 ], crash boxes [ 44 , 45 ], passive safety elements such as helmets [ 46 ], car parts [ 47 ], and even biomedical applications [ 48 ]. The tunable and designable properties of lattice structures make them compelling for space applications [ 49 ] to achieve parameters that cannot be satisfied by traditional manufacturing methods.…”

Section: Introductionmentioning

confidence: 99%

Design and Study of Fractal-Inspired Metamaterials with Equal Density Made from a Strong and Tough Thermoplastic

2023

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In this study, we created metamaterials consisting of square unit cells—inspired by fractal geometry—and described the parametric equation necessary for their creation. The area and thus the volume (density) and mass of these metamaterials are constant regardless of the number of cells. They were created with two layout types; one consists solely of compressed rod elements (ordered layout), and in the other layout, due to a geometrical offset, certain regions are exposed to bending (offset layout). In addition to creating new metamaterial structures, our aim was to study their energy absorption and failure. Finite element analysis was performed on their expected behavior and deformation when subjected to compression. Specimens were printed from polyamide with additive technology in order to compare and validate the results of the FEM simulations with real compression tests. Based on these results, increasing the number of cells results in a more stable behavior and increased load-bearing capacity. Furthermore, by increasing the number of cells from 4 to 36, the energy absorption capability doubles; however, further increase does not significantly change this capability. As for the effect of layout, the offset structures are 27% softer, on average, but exhibit a more stable deformation behavior.

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Additive Manufacturing for Lightweighting Satellite Platform

Cited by 13 publications

References 57 publications

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Mechanical Performance Comparison of Sandwich Panels with Graded Lattice and Honeycomb Cores

Design and Study of Fractal-Inspired Metamaterials with Equal Density Made from a Strong and Tough Thermoplastic

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