Compliant mechanisms and space grade product redesign based on additive manufacturing

Saudan, Hervé; Kiener, Lionel; Perruchoud, Gérald; Kruis, Johan; Vaideeswaran, Kaushik; Dadras, M.; Cochet, F.; Liberatoscioli, Sandro

doi:10.1117/12.2312087

Cited by 6 publications

(4 citation statements)

References 3 publications

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“…A novel design concept based on an Additive Manufacturing, enabling the development of mechanical parts featuring built-in electrical wires and interfaces has been developed and tested [2] & [3]. The concept has been successfully applied to re-design the rotor of a SlipRing Assembly (SRA) intended for space applications.…”

Section: Redesign Of a Slip Ring Rotor Assemblymentioning

confidence: 99%

“…Today, this paradigm is questioned by the possibilities offered by AM technologies, notably the metallic powder bed processes such as the Selective Laser Melting (SLM). After more than 30 years of successful developments using compliant mechanisms produced by conventional manufacturing methods, CSEM demonstrated in 2016 the feasibility of high performances compliant structures made by AM [1].…”

Section: Introductionmentioning

confidence: 99%

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Innovative concept of compliant mechanisms made by additive manufacturing

et al. 2019

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The complete redesign for Additive Manufacturing of compliant mechanism structures enables CSEM to develop innovative concepts to drastically reduce the need of machining and assembly after additive manufacturing. Support structures under flexure blades are thus minimised and the overall process becomes more streamlined. Moreover, this concept allows us to easily design and produce monolithic cross flexure pivots with interlocked flexible blades. Based on this concept, CSEM is now developing new architectures of Compliant Mechanisms based on Additive Manufacturing (COMAM) for the European Space Agency (ESA) in the frame of a GSTP research project. The past and current work of design, 3D printing and testing on several compliant mechanisms are presented. These demonstrators will be used as use-case for future high-precision and harsh environment applications such as cryogenic and space.

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Section: Redesign Of a Slip Ring Rotor Assemblymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Innovative concept of compliant mechanisms made by additive manufacturing

et al. 2019

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“…15 Unlike the metal counterparts, AM ceramic mirrors have been created using a variety of AM categories, fused deposition modelling 16 (FDM; filament), stereolithography 15 (SLA; liquid resin) and binder jetting 17 (powder + a binding agent). Beyond lightweight AM mirrors, there have been a number of investigations into AM for optical housings, 18,19 opto-mechanical structures 20 and compliant mechanisms [21][22][23] for astronomy or space-based applications.…”

Section: Introductionmentioning

confidence: 99%

Understanding the role of additive manufacturing in the development of astronomical hardware

Atkins,

Chahid,

Wells

et al. 2023

Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems IV

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Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.

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“…The use of non-compliant bonding technology also made it clear the necessity to find an additive manufacturing technique in the future. The feasibility study of H. Saudan [4] proved that compliant structures can be redesigned along the rules of additive manufacturing and topology optimization. The "Additive astronomy related integrated component manufacturing" (A2IM) project, an OPTICON H2020 work package, gave a perfect opportunity for the revision of the original FAME prototype specifically from design and manufacturing technology point of view.…”

Section: Introductionmentioning

confidence: 99%