3D Systems’ AIG developed the end-to-end additive manufacturing solution for the production of the antenna array components.
3D Systems, a company specializing in additive manufacturing solutions, has announced a partnership with Airbus Defense and Space to design components for the OneSat satellite, which is scheduled to enter service in 2023.
OneSat is the name of a series of satellites built by Airbus Defense and Space for satellite telecommunications services from geostationary orbit. The companies have signed a multi-year contract for the development of antennas for the entire OneSat fleet.
3D Systems’ Application Innovation Group (AIG), made up of engineers and experts, was asked to develop an end-to-end additive manufacturing solution, which includes materials, 3D printing technology, software and mastery of applications, for the production of critical components of the antenna array of these “fully reconfigurable” satellites.
Lightening of parts and printing speed
The production of such components by additive manufacturing will provide “the freedom of design required to lighten the parts, optimize their performance and accelerate their marketing”, specifies the specialist in a press release.
3D Systems has already collaborated with the Airbus division, notably around the development of the first 3D-printed radio frequency (RF) filter, intended for use in commercial telecommunications satellites.
Each OneSat satellite requires two large antenna arrays, one to transmit signals and the other to receive them. As part of this project, 3D Systems relies on the DMP Factory 500 solution to mass-produce the antenna components in LaserForm AlSi10Mg with parameters developed by AIG to achieve the required layer thickness of 30 µm. , says the company.
The DMP Factory 500 solution was selected on the basis of three criteria: its manufacturing volume (500 mm x 500 mm x 500 mm), its precision and its printing speed. In addition, “the intelligent multi-laser configuration of this printer makes it possible to produce large parts without welding”, specifies the company.
Innovative criterion
AIG also provides project management. As such, the company has identified subcontractors capable of taking care of the post-processing and quality control of the parts. 3D Systems is also leading the technology transfer process to enable “a Tier 1 supplier to ramp up production of these fully qualified components,” she says.
“Our long-standing partnership with Airbus Defense and Space is very important to us, and we are pleased to see that the work we are doing together continues to bear fruit in the telecommunications satellite sector,” said Michael Shepard, Vice President -president of the aerospace and defense segment of 3D Systems.
“OneSat is a truly revolutionary product, and we wanted our design and manufacturing process to feature that same level of innovation,” adds Stephen Phipps, OneSat Antenna Program Manager at Airbus Defense and Space. “All aspects, from the quality of the printed parts to the qualification of the parts, including quality management and overall project management, have helped Airbus Defense and Space to maintain its leading position. »