North West
Feed Cluster 2x2
The component is an RF Feed Antenna that has been…
CATEGORY
Space
MATERIAL
AlSi10Mg
Additive Manufacturing is reaching outer space. Where every gram counts, in an environment with extreme cyclic temperature variations and harsh forces during the launch, the functional life of components is a critical part of design considerations. Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
About the Project
AM Competencies Used
Additive Design & Engineering
Wipro 3D used its extensive experience in Additive Design of various structural elements, reduction of joints, and feature optimization to derive maximum value from the Additive fr Engineering principles
Post Processing Optimization
A series of well-planned operations were incorporated into the realization strategy with a coordinated effort to allow final coating operations within the customer’s site.
Build Technology Optimization
The component with a height of approximately 320 mm was built in an EOS M280, that required out-of-the-box thinking in build preparation, customized parameters and dimensional accuracy to meet 2 mm wall thickness throughout the z-axis geometry
AM Value Addition
Assembly Integrated Into A Monolith
Speed Of Iterations
The complete redesign to realize lifecycle for the component including the validation tests (Assembly Vibration Test, Climatic Test and RF Test) was completed in a period of 16 -20 weeks.
Functional Performance
RF efficiency was improved by way of reduction of initial planned joints. The component is brought into service and has been established to perform satisfactorily. With the sa strategically designed, angled and placed cross struts, the structural integrity requirements of the component to counter vibrations during launch were met.
Other Case Studies
Closed Impeller
Additive Manufacturing is reaching outer space. With increased effectiveness and maturity of space programs all over the world, leaders in the space community, are innovating, developing and iterating on multiple frontiers that lead to faster and cheaper deployment of payloads . The Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles to meet such requirements.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
LPFT Straightener
Additive Manufacturing is reaching outer space. Where every gram counts, in an environment with extreme cyclic temperature variations and harsh forces during the launch, the functional life of components is a critical part of design considerations. Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
High Pressure Compressor Stator
The Aerospace industry has been at the forefront of adapting Metal Additive Manufacturing (AM) and some of the most evolved applications of metal AM can be found in the aerospace sector. Leading OEMs, tier 1 suppliers, and key ecosystem players are in the phase of developing mature capabilities in metal AM.
Typical value contribution from Metal Additive T Manufacturing comes in form of weight reduction, reduction in sub-assembled parts by creating monolithic designs, ability to realize complex designs and drastic reduction in lead time to realize components.
Antenna Integrated Helix Feed
Additive Manufacturing is reaching outer space. With increased effectiveness and maturity of space programs all over the world, leaders in the space community, are innovating, developing and iterating on multiple frontiers that lead to faster and cheaper deployment of payloads . The Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles to meet such requirements.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.