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

A holistic process flow designed and implemented for additive manufacturing of topology-optimized metallic components suitable for use on satellites is described and demonstrated with two components that are part of the Surrey Satellite Technology, Ltd. technology mission. The holistic process flow begins with part selection and includes topology optimization, finite element analysis verification, additive manufacturing, and an aggressive mechanical and material testing campaign. The case studies used in this work include a camera bracket and a satellite panel insert. Both parts were fabricated under the guidelines of the holistic process flow in a total of eight weeks from concept to verification for flight. The process flow includes verification feedback loops in the design stage and the manufacturing stage. The aggressive testing campaign that is the last step in the process flow is included in order to guarantee the mechanical fidelity of the additively manufactured, produced components intended for flight approval and to demonstrate that the project specifications are met.