3D printing technology for manufacturing satellites and other spacecraft parts, Thales Alenia Space is one of the leading major companies.
The company, a joint venture of Thales and Leonardo, first started using 3D printing in April 2015. Its TurkMenAlem MonacoSat satellite was launched with a 3D printed aluminum antenna. Since then, every satellite it sends to orbit has an equally lightweight 3D printed antenna, as well as 3D printed reflector accessories.
South Korea's 5A and 7 telecommunications satellites began operations in 2017 and were the largest 3D printed spacecraft parts ever made in Europe at the time. Today, Thales Alenia Space is putting 3D printing into mass production to build telecommunications satellite components for the company's new all-electric Spacebus Neo platform.
Spacebus Neo will be equipped with four reaction wheel brackets made of aluminum and 16 antenna deployment and pointing mechanism (ADPM) brackets: four aluminum alloys and 12 titanium alloys. The innovative 3D printed reaction wheel bracket is designed to meet the market's demand for low cost, which is now reduced by about 10%, shortened the lead time, and shortened the production plan by one to two months. The weight of the new parts has been reduced by 30% and performance has been improved.
The metal powder bed fusion technology for these parts allows highly customized mass production, making it possible to customize the design to the exact requirements of each new task. For example, the four reaction wheel brackets of each satellite are 3D printed as two sets of symmetrical parts, and the orientation angle and interface of the ADPM bracket can be adjusted according to its specific function and position on each satellite. Thales Alenia Space also integrates connectors and cable accessories directly into the overall design, which is printed as a single piece, eliminating additional assembly requirements.
To produce these large (466 x 367 x 403 mm) reaction wheel brackets, the company used a huge Concept Laser Xline 2000R metal 3D printer with a 800 x 400 x 500 mm build room.
The first four parts have been integrated on Eutelsat's Konnect satellite, which was successfully delivered earlier this month. Other Spacebus Neo platforms will also introduce organically designed 3D printed parts in the near future.
"From design to final delivery, Eutelsat is now fully involved in the development and use of 3D printed satellite components," said Eutelsat engineer Philippe Sicard. "These components can be identified by their highly special design. To ensure the strictest quality standards, and the entire process and individual components are traceable, we have established a comprehensive testing and inspection process."