Additive Manufacturing of Lightweight, Optimized, Metallic Components Suitable for Space Flight

Orme, Melissa; Gschweitl, Michael; Ferrari, Michael; Vernon, R. Fox; Madera, Ivan; Yancey, R. N.; Mouriaux, Franck

doi:10.2514/1.a33749

Cited by 38 publications

(21 citation statements)

References 2 publications

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“…Engineers can leverage such properties to achieve substantial mass reductions, especially in the aerospace sector (Emmelmann et al, 2011). Scholars have identified three features allowing the reduction of the weight of parts: bionic design, lattice structures and thin-walled structures (Orme et al, 2017). According to interviewees, engineers can also pursue functional integration.…”

Section: Enhanced Designsmentioning

confidence: 99%

Value-driven clustering of industrial additive manufacturing applications

Fontana¹,

Klahn

Meboldt

2019

JMTM

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Purpose A prerequisite for the successful adoption of additive manufacturing (AM) technologies in industry is the identification of areas, where such technologies could offer a clear competitive advantage. The purpose of this paper is to investigate the unique value-adding characteristics of AM, define areas of viable application in a firm value chain and discuss common implications of AM adoption for companies and their processes. Design/methodology/approach The research leverages a multi-case-study approach and considers interviews with AM adopting companies from the Swiss and central European region in the medical and industrial manufacturing industries. The authors rely on a value chain model comprising a new product development process and an order fulfillment process (OFP) to analyze the benefits of AM technologies. Findings The research identifies and defines seven clusters within a firm value chain, where the application of AM could create benefits for the adopting company and its customers. The authors suggest that understanding the AM process chain and the design experience are key to explaining the heterogeneous industrial maturity of the presented clusters. The authors further examine the suitability of AM technologies with agile development techniques to pursue incremental product launches in hardware. It is clearly a field requiring the attention of scholars. Originality/value This paper presents a value-driven approach for use-case identification and reveals implications of the industrial implementation of AM technologies. The resultant clustering model provides guidance to new AM adopters.

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Section: Enhanced Designsmentioning

confidence: 99%

Value-driven clustering of industrial additive manufacturing applications

Fontana¹,

Klahn

Meboldt

2019

JMTM

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“…Recently, AM technologies were applied to the direct production of end-use parts and whole products (termed rapid manufacturing (RM)) [2,6,8,[28][29][30][31]. The AM technologies employ plastics, metals, ceramics, composites, and biological materials as deposited materials [1,4,8,[24][25][26][27][28][30][31][32][33]. In order to create metallic parts using a plastic product fabricated by the plastic based AM processes, secondary processes are additionally needed [30,31].…”

Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

318

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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“…With two separate feedback loops, the holistic process-flow includes verification steps that are incorporated to insure that: (a) the optimized design can withstand the specified loading conditions (first feedback loop) and (b) the mechanical integrity and performance of the manufactured component is suitable for conditions in which it will be employed (second feedback loop). The process flow is discussed in more detail elsewhere [3,4,22]. Note that the topology optimization routine that is employed in this work is the commercially available Altair Hyperworks software package, which, at the time of this work, did not include the AM considerations described above, and hence these are included in manual iterative loops.…”

Section: Holistic Process Flowmentioning

confidence: 99%

Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware

Orme¹,

Madera²,

Gschweitl

et al. 2018

Designs

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Three case studies utilizing topology optimization and Additive Manufacturing for the development of space flight hardware are described. The Additive Manufacturing (AM) modality that was used in this work is powder bed laser based fusion. The case studies correspond to the redesign and manufacture of two heritage parts for a Surrey Satellite Technology LTD (SSTL) Technology Demonstrator Space Mission that are currently functioning in orbit (case studies 1 and 2), and a system of five components for the SpaceIL’s lunar launch vehicle planned for launch in the near future (case study 3). In each case, the nominal or heritage part has undergone topology optimization, incorporating the AM manufacturing constraints that include: minimization of support structures, ability to remove unsintered powder, and minimization of heat transfer jumps that will cause artifact warpage. To this end the topology optimization exercise must be coupled to the Additive Manufacturing build direction, and steps are incorporated to integrate the AM constraints. After design verification by successfully passing a Finite Element Analysis routine, the components have been fabricated and the AM artifacts and in-process testing coupons have undergone verification and qualification testing in order to deliver structural components that are suitable for their respective missions.

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Additive Manufacturing of Lightweight, Optimized, Metallic Components Suitable for Space Flight

Cited by 38 publications

References 2 publications

Value-driven clustering of industrial additive manufacturing applications

Value-driven clustering of industrial additive manufacturing applications

Directed Energy Deposition (DED) Process: State of the Art

Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware

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