Introducing the Nominees for the 3D Printing Industry Awards 2023
Ladies and gentlemen, it’s that time of the year again! Nominations for the 3D Printing Industry Awards 2023 are now open. As we eagerly await the winners to be announced on November 30th, let’s take a closer look at some of the leaders in the field of 3D printing.
One innovative project that caught our attention is the collaboration between the Swiss Center for Electronics and Microtechnology (CSEM), 3D Precision, and Almatech SA. Together, they have designed, 3D printed, and tested a groundbreaking Compliant Rotation Reduction Mechanism (CRRM).
Made entirely from high-performance stainless steel, the CRRM is a frictionless gear system known as a “compliant mechanism.” This mechanism enables precise rotation in aerospace components like thrusters, sensors, and telescope lenses or mirrors, all without the need for lubrication. The CRRM achieves this by utilizing bending, or “elastic deformation,” incorporating 24 flexible blades, with 16 blades that interlock.
This impressive project, named “COMAM,” began in 2018 and received funding from the General Support Technology Programme (GSTP) by the European Space Agency (ESA). CSEM took charge of designing the CRRM, 3D Precision handled the printing process, and Almatech SA conducted the performance tests.
One of the most impressive aspects of the CRRM is its monolithic structure, where the deformable and rigid parts are printed together as a single unit. This eliminates the need for time-consuming assembly and alignment. Paolo Zaltron, ESA Technical Officer, explains, “Their unusual shapes pushed the boundaries of Additive Manufacturing technologies and are the result of advanced optimization techniques that lead to unprecedented high flexibility and low mass.”
The benefits of using additive manufacturing for the production of frictionless gear systems like the CRRM are numerous. Traditional machining methods struggle with the complexity of compliant mechanisms and the requirement for precise parts that need to be verified, aligned, and fixed together. 3D printing allows for the production of monolithic shapes without assembly requirements, offering design freedom and flexibility.
The design of the CRRM employed a combination of parametric and topology optimizations. This clever approach significantly improved the mass and eigenfrequencies of the gear, resulting in a first eigenmode of over 550 Hz. With a reduction factor of 10 for rotary motion, the CRRM is especially useful for scanning, pointing, calibration, or flip mirror mechanisms.
While the overall results of the project are deemed “very encouraging,” there were some challenges during the testing phase. The distortion of the two broadboard models manufactured and tested affected the performance and lifetime test results. However, these setbacks did not diminish the groundbreaking nature of the CRRM project.
The 3D printing revolution in the aerospace industry is not limited to compliant mechanisms. We have seen other successful applications as well. For example, Australian heat transfer specialist Conflux Technology partnered with Rocket Factory Augsburg (RFA) to embed its 3D printed heat exchanger technology into an orbital rocket. The heat exchangers, made from Conflux Technology’s Monel K500 metal alloy material, were 3D printed using EOS’s M300-4 Direct Metal Laser Sintering (DMLS) technology.
The Portland State Aerospace Society (PSAS) also took advantage of 3D printing technology to successfully launch OreSat0, a CubeSat system, into low Earth orbit. CRP Technology’s Windform LX 3.0 composite material was used to produce critical subsystems of the 3D printed satellite.
As we witness these exciting developments in the aerospace industry, it becomes evident that 3D printing is a game-changer. Its ability to create complex and unique structures without assembly requirements opens up a world of possibilities. We eagerly await the winners of the 3D Printing Industry Awards 2023 to see how technology continues to push the boundaries of what is possible. Stay tuned!
Title: From Prototyping to Space: The Journey of OreSat
Introduction:
In the ever-evolving world of additive manufacturing, advanced techniques such as selective laser sintering (SLS) have revolutionized the production of complex components. This blog post delves into the remarkable story of OreSat, a satellite project that underwent prototyping before transitioning to SLS technology with Windform LX 3.0 for the final 3D printing of its parts. Join us as we explore the journey of OreSat, scheduled to launch in October 2023, and its successor OreSat1, set to deploy from the International Space Station in early 2024.
OreSat: A Project on the Horizon
The OreSat project, spearheaded by a team of talented engineers, aimed to develop a satellite that could navigate and observe Earth’s resources from space. Realizing the significance of additive manufacturing, the team initially used prototyping techniques to fine-tune their designs and gain valuable insights. This phase allowed them to identify potential improvements before proceeding to the final production stage.
Selective Laser Sintering: A Game-Changing Technique
As the project progressed, the OreSat team recognized the need for a robust and reliable production method to create the intricate components required for space exploration. This realization led them to embrace selective laser sintering (SLS) utilizing Windform LX 3.0. The SLS technique offered numerous advantages, including the ability to manufacture complex geometries and durable parts with high precision.
The Impact of 3D Printing on Space Exploration
By adopting SLS technology, the OreSat team revolutionized their manufacturing process. With 3D printing, they were able to produce components that previously would have been either time-consuming or impossible to fabricate using traditional methods. Furthermore, the lightweight and compact design of the 3D-printed parts helped optimize the satellite’s performance and reduce its overall weight, a critical factor in space applications.
The Journey Continues: OreSat1
Following the successful development and imminent launch of OreSat, the team’s aspirations knew no bounds. They set their sights on creating OreSat1, an even more sophisticated satellite scheduled to be deployed from the International Space Station. Leveraging the power of SLS with Windform LX 3.0, the team intends to push the boundaries of what is possible in space exploration.
Keeping Up with the 3D Printing Industry
As the additive manufacturing industry continues to expand its capabilities, staying informed about the latest developments is crucial. To keep up with the latest news in 3D printing, consider subscribing to the 3D Printing Industry newsletter. Additionally, follow the industry’s leading voices on social media platforms such as Twitter, Facebook, and YouTube to access exclusive content and stay ahead of the curve.
Embark on Your Additive Manufacturing Career
Are you intrigued by the vast possibilities of additive manufacturing? If so, exploring career opportunities in this rapidly growing industry might be the next step for you. Visit 3D Printing Jobs, where a variety of roles are advertised, to kickstart your career in the additive manufacturing sector.
Conclusion:
The story of OreSat showcases the transformative power of additive manufacturing in the realm of space exploration. Prototyping paved the way for the utilization of selective laser sintering (SLS) using Windform LX 3.0, enabling the team to 3D print the final parts with precision and efficiency. As OreSat prepares for launch in October 2023 and OreSat1 gears up for deployment from the International Space Station in early 2024, the possibilities for 3D printing in the space industry are limitless.
