As part of the ESA-funded project “AM Maturation”, OHB System AG and the Fraunhofer IAPT have established a complete and validated process chain for the additive manufacturing of space components. The aim was to qualify the powder bed fusion process using a laser (PBF-LB/M) to meet the demanding requirements of the space industry in terms of quality, safety, and reproducibility. The jointly developed manufacturing route was tested on three representative satellite components.
The PBF-LB/M additive manufacturing technology offers distinct advantages in the aerospace sector, particularly in terms of weight savings, functional integration, and shorter development times. At the same time, the industry is highly regulated. Therefore, the initial focus was on defining reliable design guidelines, process parameters, and testing methods. For implementation, both structural and opto-mechanical components—a connecting element, a reaction wheel bracket, and a dual mirror—were iteratively refined in terms of functionality and manufacturability.
Production was carried out under process-stable conditions using titanium and aluminum materials. Targeted topology optimization enabled weight reductions of up to 45% without compromising the required mechanical and thermal properties. The dual mirror, after optimization of its mounting points, exhibited improved thermal stability, while the reaction wheel bracket featured integrated fastening elements that made assembly easier.
In addition to the technical achievements, a key objective was to establish a scalable supply chain for qualified AM components.
Dr. Marco Mulser, Head of Technology Coordination at OHB System AG, summarized:
“With the support of Fraunhofer IAPT, OHB was able to establish a reliable process chain that now allows us to use high-quality AM components in our satellite projects.”
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
