New applications of rapid prototyping and rapid manufacturing (RP/RM) technologies for space instrumentation

Paper number

IAC-06-C2.8.05

Author

Prof. Pierre Rochus, Centre Spatial de Liège, Belgium

Coauthor

Prof. Jean-Pierre Kruth, Belgium

Coauthor

Dr. Maarten Van Elsen, Belgium

Coauthor

Mr. Thierry Dormal, Belgium

Coauthor

Mr. Jean-Yves Plesseria, Centre Spatial de Liège, Belgium

Coauthor

Mr. Raoul Carrus, Belgium

Year

2006

Abstract

The possibility to use rapid prototyping and rapid manufacturing (RP/RM) technologies during space instrument development is investigated. Rapid prototyping and rapid manufacturing terms gather several techniques with the common baseline that parts are built layer by layer, starting from a CAD model. These technologies imply powder, paste or liquid and are applicable to polymers, ceramics and metals.
In a first step, the major advantages of these techniques have been presented to Belgian industries implied in the space sector and as a result of the discussion; development goals for the project have been identified. Several types of use have also been pointed, from demonstration mock-up to real space hardware.
In parallel to technical development, several case studies and tests have been performed. A first point was to check if the current materials of RP/RM could be used under vacuum. As the best known are polymers, compatibility of the most promising ones with outgassing requirements have been checked.
The case studies have shown that the rapid manufacturing allows complex geometry. A drastic decrease of the number separate parts and bolted junctions ease the predictability of the mechanical and thermal behaviour and limit the risk of imperfect junction (that would lead to leaks, whatever of liquid, gas or light). Porous or hollow light-weight components or parts with gradient properties were also studied. Hollow structures with varying the porosity or varying the composition to realize functionally graded materials, should be possible, when the process is fully controlled. 
As a result of the project, a guidelines document has been issued to give as much information as possible on how to perform a space instrument design using the advantages of RP/RM techniques. This paper will present, through the review of some case studies and tests, the conclusions of the project.

Abstract document

IAC-06-C2.8.05.pdf

Manuscript document

IAC-06-C2.8.05.pdf (🔒 authorized access only).

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