JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 56

aerospace
LS process benefits
- Layered technology is free from geometrical constraints, making it possible to build
undercuts, hollow parts and internal ducts.
- Opportunity to build directly functional “assembled mechanisms” (minimum clearance between
parts 0.5 mm).
- Many different parts can be built together in the same building volume.
- Building time is not dependent on object geometry, but only on part volume and on build “height”
(Z dimension).
- Very short building time (max 1-2 working days).
- Very short lead time (max 2-3 working days).
- Windform parts can be machined when high dimensional accuracy is required.
- To reduce mass and weight, it is possible to create hollow parts with internal reinforcing structures.

Z build axis vertical to the satellite’s longest
axis after assembly. This allows the X and
Y axes to be positioned so as to provide
the most strength in the perpendicular axis
holding the bus together.

Bus construction
The bus underwent several revisions
within the period of a few months. Walter
Holemans was able to add experiments,
create different deployment options, and
develop wire routing and harness control
devices utilizing design techniques to
maximize the use of additive manufacturing. Increased complication was not a
hindrance to the process and allowed for
greater design freedom. The Solar Cell
experiment (Figure 10) was easily tucked
into the side of the bus, as it only required
implementing a simple feature cut in the
CAD system. A new module design was
built with the required space in the side of
the module, allowing the experiment to be
added quickly to the mission.
The bus and propulsion modules were
created in separate sections to enable the

different teams to test and assemble them
at different locations. This allowed the production of prototype modules to try ideas
based on the current challenges and then
adjust as needed. At the completion of the
final design, the parts were grown at 0.1mm layers and then sanded to a smooth
finish to aid in the plating process.
Utilizing the experimental and simulation
data, the propulsion module (pressure
vessel) was oriented such that the Z build
orientation was again parallel to the longest
axis of the CubeSat. Due to the internal
structures of the baffled cubes, the module
was subjected to an ultrasonic water bath
to ensure no material was trapped in the
chambers. The plating was completed by
Quaker City Plating (Whittier, California)
under the direction of Frank Huizar.

Conclusion
The innovative use of additive manufacturing technology has shown that this type
of technique will allow for fast adaptability
and high design freedom. Working with the
idea of utilizing additive manufacturing as a
core principle, the team was able to modify,
change, and add experiments without

concern for having to develop tooling or
modify an existing cube structure.
The development of RAMPART shows
that this type of building technique adds
value for standardized CubeSat boards
as well as for devices that do not fit easily
“into the box.” As electronics and sensor
systems become smaller and more complex, there is a push for developing more
complex and advanced CubeSats. In the
development of greater complexity, additive manufacturing opens the possibility to
adapt the structure to carry new sensors,
or optics. Utilizing CAD and additive
manufacturing, the internal structure of
the CubeSat can be built to adapt to the
components, instead of the other way
round. This allows the use of the CAD
system to adapt to new technology as it is
introduced. This eliminates the concern
for legacy systems that are being held on
the shelf, for technology that is becoming
obsolete. In addition, standard components
can be placed into a CAD library that will
allow for parametric generation of portions
of the satellite. Additive manufacturing of
the RAMPART bus module shows a clear
mixing of standard board modules and
customizing for solar panels, wire routing,
and the addition of the load cell. Another
observed benefit was the reduced number
of fasteners and ease of assembling the
RAMPART CubeSat. Positioning features
and “snap fit” devices can be incorporated
into the design methodology to speed
assembly. The extensive baffle design in the
tank structure of the satellite leverages this
consolidation of components, eliminating
the need for a complicated assembly. n
More information:
www.windform.eu

Items to consider when designing for the SLS process

Fig. 10: Solar Cell experiment added to RAMPART’s
bus module

- Building volume (360x310x380 mm). To build big objects, it is necessary to produce piece by
piece and then bond them together with approved materials.
- The minimum feasible wall thickness is 1 mm. The ideal value is 1.5-2 mm.
- Minimum feasible details >=1 mm.
- It is important to avoid enclosed volumes: hollow parts will need a hole or some type of gate
to allow the removal of loose or un-melted powder.
- When designing parts to be assembled together, a minimum 0.2 mm clearance should always
be kept between them.
- Excessive wall thickness (>10 mm) can cause unwanted warping and shrinkage on parts.
- After the LS process, roughness is high (Ra 6 mm) and Z layering is visible. External surfaces
can be smoothed to reduce it to Ra 1.5 mm.

56 jec composites magazine / No78 January - February 2013


http://www.windform.eu

JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013

Cover
Edito
Point of view: bespoke solutions
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
- Glass fibre
APPLICATIONS
- Bridge
- Music instrument
MARKET Overview 2012
FEATURE WIND ENERGY
- Market
- Resin
- Structure
- Prepreg
- Natural fibre
- China
RESEARCH & DEVELOPMENT
- Repair
- Bonding
TECHNOLOGY & INNOVATIONS
- RTM
- Laminate
- Aerospace
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Point of view: bespoke solutions
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 10
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 12
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Bridge
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 14
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Music instrument
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - MARKET Overview 2012
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 18
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 19
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 20
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 22
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 23
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Market
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 26
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Resin
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 28
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Structure
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Prepreg
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 33
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Natural fibre
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 35
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 36
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - China
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 40
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Repair
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 43
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Bonding
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 45
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - RTM
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 48
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Laminate
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 51
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 52
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - - Aerospace
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 54
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 55
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 56
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 59
JEC COMPOSITES MAGAZINE - Issue #78 - January/February 2013 - 60
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