Motivations, Opportunities and
Challenges of Additive Manufacturing
for Space Application
Franck Mouriaux
General Manager Structures
RUAG Schweiz AG
RUAG Space
Paris, October 1st 2015
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manf’
flexibility
for free
design
complexity
for free
design
MASS
reduction
lead
TIME
reduction
function
integration
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Why
AM?
FREEDOM
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SUPPLIER
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PRODUCT
post-
processing verification
How
AM?
qualification
design analysis
PROCESS MATERIAL
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Where
AM?
EVERY
WHERE
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SENTINEL-1
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Original Design
1.6kg
88.7Hz
163MPa
2
First Optimisation Loop
1.2kg
88.7Hz
1
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Original design
enveloppe
Original
interfaces
Original
loading
Original
electrical
grounding
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Original design
enveloppe
Original
interfaces
Original
loading
Original
electrical
grounding
?
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What do I want? Design objective
What can I change? Design parameters
What targets must be met? Design constraints
+ +
Size
Topology Shape
optimization of
material layout
optimization of
element properties
optimization of part
shape
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Function
Testing
Post-process
Integration
Printing
DESIGN
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Printed on an EOS M400 from the company CITIM.
Material: AlSi10Mg
(AA357-AA359 casting alloy)
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Qualification Flight
Geometrical verification
Modal verification
Quasi-static load test
Sine vibration tests (3-dir.)
Random vibration tests (3-dir.)
Vibration Test
Geometrical verification
Modal verification
Quasi-static load test
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CMM Computer Tomography (CT Scan) CT Scan
Eddy Current
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In-plane (XZ) low level sine sweep to verify the frequency requirement.
Frequency search spectrum
Frequency [Hz] Amplitude [g] Speed [oct/min] direction
5 to 2000 0.2 2 One sweep up
TEST RESULTS Predicted Measured
1st Eigen frequency (X) 90.0 Hz 91.4 Hz
2nd Eigen frequency (Z) 106.9 Hz 109.0 Hz -X
Z
X-response
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SG09: 246
Strength verification under static, sine and random loading.
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SG08: 282
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Rupture test.
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Topology
Optimisation
Design / Optimisation Manufacturing Verification / Testing
Functional analysis
Topology optimisation
CAD Interpretation
Size/Shape Optimisation
Detail Stressing
Optimisation
Post-Processing
Samples Definition
Process Control
Quality Control
Test Definition
Qualification Testing
Model Correlation
CAD
Interpretation Manufacturing Verification
Testing
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Main Challenges…
of the technology by customers and authorities
and control of the materials and processes
of additive manufacturing technologies
of new engineering thinking
of new design tools
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Thank you for your attention!
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Franck Mouriaux
General Manager Structures
RUAG Schweiz AG
RUAG Space
Schaffhauserstrasse 580
8052 Zürich · Switzerland
Tel. +41 44 306 21 37
Fax. +41 44 306 27 50
Mobile: +41 78 709 56 71
franck.mouriaux@ruag.com
http://www.ruag.com