In collaboration with LISI Aerospace Additive Manufacturing and Thales Alenia Space France, the Swiss Technology Innovation Center CSEM has developed a 3D-printed tube segment that combines heating elements and temperature sensors. The component was designed as part of the EU project AHEAD (Advanced Heat Exchange Devices). It is to be used in the thermal control systems of satellites. In addition to satellite technology, the concept could also be of interest in other areas, such as IoT applications.
The pipe segment is used in Mechanically Pumped Loops (MPLs), which circulate fluids such as ammonia to transfer heat from hot to cold areas. The segment heats the coolant locally and simultaneously measures the temperature to control thermal regulation. It is made from 316L stainless steel and manufactured using Laser Powder Bed Fusion (LPBF). The component weighs 115 grams, is 150 millimeters long and can operate in a temperature range of -65 °C to +85 °C at a pressure of up to 48 bar.
The design integrates heating wires, sensors and connections directly into the tube structure. This additive manufacturing eliminates the need to glue or wire separate components. According to Hervé Saudan, project manager at CSEM, the design ensures even heat transfer as the heating wires are optimally arranged around the tube. This avoids errors such as delamination or cable separation.
The production also required special design solutions to ensure electrical insulation between the wires and the tube structure. This was achieved using support structures that were removed after production. The developers have applied for a patent for this method.
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