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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 07.10.2015 │RUAG Space│ 2 Why AM? FREEDOM

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SUPPLIER 07.10.2015 │RUAG Space│ 3 PRODUCT post- processing verification How AM? qualification design analysis PROCESS MATERIAL

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07.10.2015 │RUAG Space│ 4 Where AM? EVERY WHERE

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07.10.2015 │RUAG Space│ 5 SENTINEL-1

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07.10.2015 │RUAG Space│ 6 Original Design 1.6kg 88.7Hz 163MPa 2 First Optimisation Loop 1.2kg 88.7Hz 1 SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 7 Original design enveloppe Original interfaces Original loading Original electrical grounding SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 8 SENTINEL-1 Antenna Support Bracket Original design enveloppe Original interfaces Original loading Original electrical grounding ?

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07.10.2015 │RUAG Space│ 9 SENTINEL-1 Antenna Support Bracket 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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07.10.2015 │RUAG Space│ 10 SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 11 SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 12 SENTINEL-1 Antenna Support Bracket 2 3 1

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07.10.2015 │RUAG Space│ 13 SENTINEL-1 Antenna Support Bracket Function Testing Post-process Integration Printing DESIGN

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07.10.2015 │RUAG Space│ 14 Printed on an EOS M400 from the company CITIM. Material: AlSi10Mg (AA357-AA359 casting alloy) SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 15 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 SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 16 CMM Computer Tomography (CT Scan) CT Scan Eddy Current SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 17 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 SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 18 SG09: 246 Strength verification under static, sine and random loading. SENTINEL-1 Antenna Support Bracket SG08: 282

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Rupture test. SENTINEL-1 Antenna Support Bracket

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07.10.2015 │RUAG Space│ 20 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 SENTINEL-1 Antenna Support Bracket

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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! 07.10.2015 │RUAG Space│ 22 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 [email protected] http://www.ruag.com