Airbus Defence and Space Uses EOS Additive Manufacturing Process for the Optimized Production of Satellite Parts

Airbus Defence and Space Uses EOS Additive Manufacturing Process for the Optimized Production of Satellite Parts

CHENNAI, India, September 24, 2015 /PRNewswire/ --

    - Cross reference: Picture is available via epa european pressphoto agency
(http://www.epa.eu) -

    The Airbus Defence and Space division, one of the world's leading suppliers of
satellite and space transport technology, relies on EOS, global technology and quality
leader for high-end Additive Manufacturing (AM) solutions, for the optimized production of
satellite parts.

    Airbus Defence and Space's portfolio ranges from satellite systems to components for
the International Space Station ISS, where part requirements are particularly high because
of the tremendous temperature differences and external forces involved.

    The current generation of satellites includes specific brackets that serve as a link
between the body of the satellite and the reflectors and feeder facilities mounted at its
upper end. Originally, the engineers faced two key challenges with regards to the design
of these retaining brackets: They must fix securely to the body, yet have to mitigate the
extreme temperature fluctuations in space and serve as a layer of insulation as
temperatures range from -180 to +150 degree(s)C. So the stress on the material is
extremely high and very few materials can meet these requirements. Titanium turned out to
be the appropriate material choice due to its weight and thermal conductivity as well as
an acceptable density. After all, every kilogram carried into space costs many thousand
dollars.  

    Brackets manufactured conventionally and especially their connection with the carbon
components of the satellite did not meet their expectations. Subsequent installation on
the satellite component was very time-consuming so costs needed to be reduced as well. As
such, the engineers began looking for alternatives with the aim of optimizing the design
of future components accordingly.

    The company finally chose the Metal AM technology offered by EOS which also enabled
them to continue using titanium that was already a tried and tested material. Component
design as such could easily be adapted and production itself optimized. Today, Airbus
Defence and Space manufactures the part in a single step on an EOSINT M 280 Direct Metal
Laser Sintering System (DMLS) which meets all expectations. The temperature resistance of
the entire structure could be improved, which now can easily and permanently withstand a
margin of 330 degree(s)C under a force of 20 kN. This also significantly reduces thermally
induced failure during the qualification test campaign.

    In sum, AM brought measurable benefits to critical aspects of the project without the
need for compromising elsewhere. In addition to the technical advantages, targeted cost
reductions were achieved as savings in production alone amount to more than 20%. Moreover,
the weight advantage of the part is about 300 g, which means nearly one kilo per
satellite. Production time of the brackets during assembly of feed and sub reflector units
could be reduced by five days. Production time of the three brackets required for each
satellite is now less than a month.

    Please find the complete English case story here
[http://www.eos.info/case_studies/additive_manufacturing_technology_otimizes_satellite_technology ]
. For further information please contact Stephanie Cheong, Marketing Manager EOS
Singapore Pte. Ltd. (phone +65-6430-0541, e-Mail: Stephanie.cheong@eos.info).

EOS India