3D Systems to additively manufacture critical satellite components for Airbus OneSat

May 12, 2022

3D Systems’ AIG designed an end-to-end AM solution – comprising its DMP Factory 500, materials, software and applications expertise – to deliver fully-qualified processes and components required for the satellite’s large antenna array (Courtesy 3D Systems)
3D Systems’ AIG designed an end-to-end AM solution – comprising its DMP Factory 500, materials, software and applications expertise – to deliver fully-qualified processes and components required for the satellite’s large antenna array (Courtesy 3D Systems)

3D Systems, Rock Hill, South Carolina, USA, has announced that the company has been selected by Airbus Defence and Space to produce critical components for its OneSat satellite. 3D Systems’ Application Innovation Group (AIG) has designed an end-to-end Additive Manufacturing solution – comprising materials, AM technology, software and applications expertise – to produce the components required for the large antenna array on these satellites.

Additively manufacturing these components offers the design freedom to enable weight reduction, part performance optimisation, and faster time to market which aids in more rapid deployment of these unique satellites.

3D Systems has worked with Airbus Defence and Space over the past seven years. Previous collaborations include the production of the first additively manufactured radio frequency (RF) filter tested and validated for use in commercial telecommunications satellites and the production of innovative switch assembly network designs for two Eurostar Neo spacecraft as part of the first large-scale deployment of RF products using Additive Manufacturing.

Each OneSat satellite requires two large antenna arrays, one to transmit signals and one to receive. 3D Systems’ DMP Factory 500 Solution will be employed for serial production of the antennae components using LaserForm AlSi10Mg and specific parameters developed by the AIG for this application to achieve the required 30 µm layer thickness.

Airbus’ OneSat is based on a standard, modular and design-to-manufacture approach, and can be delivered more quickly than existing telecoms satellites and at a reduced cost (Courtesy Airbus)
Airbus’ OneSat is based on a standard, modular and design-to-manufacture approach, and can be delivered more quickly than existing telecoms satellites and at a reduced cost (Courtesy Airbus)

The DMP Factory 500 was reportedly selected for this project based on its build volume (500 x 500 x 500 mm), accuracy, and rapid build speed. The multi-laser configuration of this Additive Manufacturing machine enables the production of seamless large parts resulting in high surface quality and material properties. The AM machine includes a unique vacuum chamber that allows for the lowest possible oxygen content in the build chamber, thus protecting chemical composition and reducing the moisture content of the metal powder alloys during manufacturing. This is said to ensure optimum operating conditions for consistent part quality (eg mechanical properties and surface homogeneity), which is necessary for an industry with such high requirements for quality and precision. The DMP Factory 500 also includes 3DXpert® which supports every step of the Additive Manufacturing workflow from design to post-processing, to quickly and efficiently transition from a 3D model to successfully additively manufactured parts.

In addition to providing design and production expertise, 3D Systems’ AIG is also acting in the capacity of project manager. The company has identified subcontractors that are conducting post-processing and quality inspection, thus delivering a comprehensive end-to-end solution designed to help Airbus Defence and Space mitigate risk and reduce time to market. The AIG is also leading the technology transfer process, whereby they will enable another tier 1 supplier to quickly ramp production of these fully-qualified components. The supplier is also purchasing another DMP Factory 500 to complement its existing fleet and allow it to meet the quality levels required by Airbus.

“We value our long-standing partnership with Airbus Defence and Space, and are pleased with how our collective work continues to make its mark in telecommunications satellites,” stated Dr Michael Shepard, vice president, aerospace & defence segment, 3D Systems. “As with our earliest work with Airbus on the first additively manufactured RF filter, we have the opportunity to bring another ‘first’ to the industry that is changing telecommunications. Our AIG has laid the groundwork for developing the application for this component and completing the technology transfer. We’re proud that 3D Systems’ technology can help lay the foundation for Airbus to build a strong supply chain for serial production of passive RF hardware.”

Stephen Phipps, OneSat antenna programme manager, Airbus Defence and Space, added, “OneSat is a truly disruptive product, and we wanted our design and manufacturing process to possess that same level of innovation. Our company has a strong partnership with 3D Systems and has relied on its team of application engineers to help us bring our most advanced designs to life. Everything from the quality of the parts produced using their printers, through to parts qualification, quality management, and overall project management have helped Airbus Defence and Space maintain its position as an industry leader.”

www.airbus.com

www.3dsystems.com

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