3-D printing and its role in the new-age space race

Following the successful Jupiter Icy Moons Explorer (JUICE) mission launch last year, which included components 3-D printed on a Renishaw RenAM 500 series metal additive manufacturing (AM) system, Marc Gardon, AM applications manager at global engineering technologies company Renishaw, recently spoke to Marta García-Cosío Carmena, CiTD managing director, and Lidia Hernández Álvarez, CiTD head of AM.

Following an eight-year journey to get there, the four-year JUICE mission will explore the Jovian system, focusing on three of Jupiter’s huge Galilean moons: Europa, Ganymede and Callisto, which are as large as dwarf planets and covered by an icy crust. Once the spacecraft enters Jupiter’s gravitational field, the first two-and-a-half-years of its four-year mission will be spent making about 30 observation overflights of the three moons, observing examining gravity and magnetic interactions, among other things. The last year will be spent in orbit around Ganymede to observe this moon in much greater detail.

However, the challenges are enormous, as JUICE must deal with very low and very high temperatures as it will circle Earth, Mars and Venus for gravity assist manoeuvres to build up enough speed to reach Jupiter’s orbit. Jupiter’s cold environment also makes it hard to collect energy.

Recent advancements in technologies such as sensors and microprocessors has led to the miniaturisation of components for communication, data processing and more. Combined with the development of new composites, such as carbon fibre and other lightweight alloys, it has become easier to develop smaller, more affordable satellite platforms which has made a mission such as JUICE achievable. As a result, space agencies and research institutions are now not the only companies operating in the space industry, with many private companies looking to develop the commercial opportunity to provide services for smaller satellites.



The space industry differs from other sectors, such as consumer goods or commercial aerospace, because of production rates. Space agencies will develop individual satellites during a project, while small companies will produce small batches of components — manufacturers will rarely produce more than 100 units, and every product will be highly customised. As a manufacturing method, metal AM is well suited to rapid prototyping and the low-volume production of such components, so there is a clear opportunity for manufacturers in the space sector to embrace AM technology.

Ms Carmena, explained: “As the industry becomes more competitive, reducing lead times and costs while maintaining quality and reliability will continue to be a key challenge. We now have access to a range of new manufacturing methods and materials that mean we can design optimal parts for a range of applications. However, to have the skills and technologies available to develop platforms quickly to the tight tolerances required in aerospace, can be costly for companies.

“To find the right balance between cost and efficiency, manufacturers should take the time to understand all operational requirements at the outset of the project. Space satellite platforms must meet tight tolerances to ensure performance and precision — any deviation when operating in a harsh environment like space can lead to malfunction and even mission failure. As a result, manufacturers often have to deliver under pressure to meet deadlines and stay ahead of the competition.”

Costly technology
She continued: “The space industry is incredibly competitive, so we often find that manufacturers are more willing to take calculated risks to balance cost, performance and speed. While it is clear that AM offers the speed and design flexibility required in these applications, it is a costly technology, so manufacturers should consider how to find the best balance. For example, when approaching a new product, clearly, it is vital to comply with all the requirements, although it is necessary to understand where they come from and if they can be reformulated while still maintaining performance.”

Metal AM has been a useful tool in the production of components with complex geometries, giving manufacturers like CiTD the ability to design and manufacture parts with better performance when compared with traditional manufacturing methods. However, it is important to understand that AM technologies complement traditional methods, and does not replace them. Subtractive and AM offer different benefits and drawbacks and the most robust approach for space applications is to use a combination of the two when developing components — merging the accuracy and reliability of traditional manufacturing with thr design freedom afforded by AM.

Ms Álvarez added: “The most successful use cases are those where the AM process and material properties provide added value. Traditional manufacturing has decades of heritage, so there are always applications where machining, injection moulding or other methods may be preferable. However, changes in regulations, pressure from lead times and the need for mass reduction and lightweighting means that AM can be a valuable alternative, despite the cost.

“Determining the best manufacturing method requires engineers to review the part and its performance. If AM can improve part performance, such as delivering better conductivity or strength to weight ratio, it will add value to the final component. Parts such as heat exchangers and radio frequency (RF) antennas are good examples of where to use AM, because engineers can optimise the geometry to improve efficiency. Alternatively, when developing simple yet core components, such as flat plates, AM adds no value to its properties, so it will always be better to use traditional machining processes.”

To explore Jupiter’s complex environment, ESA launched the JUICE mission. Working in collaboration with Airbus Defence and Space, Catec and CiTD, ESA set an objective to optimise the structure of the explorer and reduce its weight as much as possible.

High-performance parts
Ms Carmena, continued: “Our team helped produce 11 secondary structure brackets for the JUICE project, using AM technology to deliver lightweight, high-performance parts. By using high-strength aluminium alloys, optimising component design and collaborating with the other AM specialists on the project, we were able to produce brackets that were 50% lighter than traditional ones.”

The project was also a unique experience for Renishaw, as it marked the first time that any product featuring parts manufactured on a Renishaw RenAM 500 system would travel to Jupiter and its satellites. As AM technology advances, improved productivity will help lower cost per part and open the technology to new applications. In terms of space applications, any development should improve the robustness of the process and ensure that parts can meet the tight tolerances expected in the sector.

Ms Álvarez concluded: “Part inspection and verification will be integral to the future of AM in space applications. Manufacturers must currently test all iterations of a part, including prototypes and final units, at the end of production, using CT scanning to ensure there are no internal defects. Currently, this process can be costly, as manufacturers may only be able to see defects after a build is complete, causing manufacturers to scrap the part. So, to improve the robustness of the process, AM users are considering how to reduce the cost of verification and control measures. As a result, process monitoring tools and artificial intelligence will be key to the future of AM in space applications.”

As companies compete to capitalise on the burgeoning opportunities in space exploration, the convergence of subtractive and AM methods presents manufacturers with the design freedom to develop unique components as well as the accuracy to meet stringent demands. By focusing on precision, performance and cost-effectiveness, manufacturers can expect AM to help develop groundbreaking advancements in future space applications.

For further information on the benefit of Renishaw AM systems in space applications, visit the website here.