SAMPE Journal - November/December 2021 - 48
FEATURE
Additive Manufactured Lattice
Development and Validation of Additive Manufactured
Lattice Structure Spacecraft Components
Nicholas Eaton
Space Acoustics GmbH, Rafz, Switzerland
M. Komarek
L.K Engineering S.R.O, Brno, Czech Republic
Email: nick@space-acoustics.com
ABSTRACT
S
pace Acoustics participated in a European Space Agency technology application study, performed by LK
Engineering (Brno), NETME (Brno) & Thales Space (Cannes), with the objectives of designing, manufacturing
& qualifying lightweight tertiary structures for spacecraft. The potential of additive manufacturing to achieve
significant advantages over conventionally manufactured parts provides a clear motivation to apply them for
space, however their repeatability and quality has to be proven by stringent process and materials control, with
many factors to be considered. This study focused mainly on design optimisation, process qualification, and
functional strength/stiffness and vibration tests representative of space. Validation of manufacturing processes
including raw materials, heat-treatment, post-machining, cleaning, in-process coupon sampling, X-ray CT
inspection and metrology. Qualification testing using high level sine and random tests were used to validate
the design methodologies and prove the durability of the manufactured parts. The structural requirements
of the antenna bracket were optimally achieved using a hybrid design, combining a lightweight lattice type
structure with reinforcing embedded frame. The successful design of lightweight lattice type structures using
topology optimisation supported by FEM analysis and with corrections based on observed manufacturing
details was proven by strength and stiffness tests. The tolerance to structural overloading was checked by
increasing the applied vibration loading above the design limits, a gradual degradation was observed, and
was closely correlated with predictions. The know-how and experience gained in developing the spacecraft
antenna mounting and other parts is being applied in further parts, mainly in Titanium, Aluminium and Inconel
materials, in a larger and contemporary ALM manufacturing facility type EOS M400.
48 | SAMPE JOURNAL | NOVEMBER/DECEMBER 2021
www. sampe.org
http://www.sampe.org
SAMPE Journal - November/December 2021
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2021
SAMPE Journal - November/December 2021 - Cover1
SAMPE Journal - November/December 2021 - Cover2
SAMPE Journal - November/December 2021 - 1
SAMPE Journal - November/December 2021 - 2
SAMPE Journal - November/December 2021 - 3
SAMPE Journal - November/December 2021 - 4
SAMPE Journal - November/December 2021 - 5
SAMPE Journal - November/December 2021 - 6
SAMPE Journal - November/December 2021 - 7
SAMPE Journal - November/December 2021 - 8
SAMPE Journal - November/December 2021 - 9
SAMPE Journal - November/December 2021 - 10
SAMPE Journal - November/December 2021 - 11
SAMPE Journal - November/December 2021 - 12
SAMPE Journal - November/December 2021 - 13
SAMPE Journal - November/December 2021 - 14
SAMPE Journal - November/December 2021 - 15
SAMPE Journal - November/December 2021 - 16
SAMPE Journal - November/December 2021 - 17
SAMPE Journal - November/December 2021 - 18
SAMPE Journal - November/December 2021 - 19
SAMPE Journal - November/December 2021 - 20
SAMPE Journal - November/December 2021 - 21
SAMPE Journal - November/December 2021 - 22
SAMPE Journal - November/December 2021 - 23
SAMPE Journal - November/December 2021 - 24
SAMPE Journal - November/December 2021 - 25
SAMPE Journal - November/December 2021 - 26
SAMPE Journal - November/December 2021 - 27
SAMPE Journal - November/December 2021 - 28
SAMPE Journal - November/December 2021 - 29
SAMPE Journal - November/December 2021 - 30
SAMPE Journal - November/December 2021 - 31
SAMPE Journal - November/December 2021 - 32
SAMPE Journal - November/December 2021 - 33
SAMPE Journal - November/December 2021 - 34
SAMPE Journal - November/December 2021 - 35
SAMPE Journal - November/December 2021 - 36
SAMPE Journal - November/December 2021 - 37
SAMPE Journal - November/December 2021 - 38
SAMPE Journal - November/December 2021 - 39
SAMPE Journal - November/December 2021 - 40
SAMPE Journal - November/December 2021 - 41
SAMPE Journal - November/December 2021 - 42
SAMPE Journal - November/December 2021 - 43
SAMPE Journal - November/December 2021 - 44
SAMPE Journal - November/December 2021 - 45
SAMPE Journal - November/December 2021 - 46
SAMPE Journal - November/December 2021 - 47
SAMPE Journal - November/December 2021 - 48
SAMPE Journal - November/December 2021 - 49
SAMPE Journal - November/December 2021 - 50
SAMPE Journal - November/December 2021 - 51
SAMPE Journal - November/December 2021 - 52
SAMPE Journal - November/December 2021 - 53
SAMPE Journal - November/December 2021 - 54
SAMPE Journal - November/December 2021 - 55
SAMPE Journal - November/December 2021 - 56
SAMPE Journal - November/December 2021 - 57
SAMPE Journal - November/December 2021 - 58
SAMPE Journal - November/December 2021 - 59
SAMPE Journal - November/December 2021 - 60
SAMPE Journal - November/December 2021 - 61
SAMPE Journal - November/December 2021 - 62
SAMPE Journal - November/December 2021 - 63
SAMPE Journal - November/December 2021 - 64
SAMPE Journal - November/December 2021 - 65
SAMPE Journal - November/December 2021 - 66
SAMPE Journal - November/December 2021 - 67
SAMPE Journal - November/December 2021 - 68
SAMPE Journal - November/December 2021 - 69
SAMPE Journal - November/December 2021 - 70
SAMPE Journal - November/December 2021 - 71
SAMPE Journal - November/December 2021 - 72
SAMPE Journal - November/December 2021 - 73
SAMPE Journal - November/December 2021 - 74
SAMPE Journal - November/December 2021 - 75
SAMPE Journal - November/December 2021 - 76
SAMPE Journal - November/December 2021 - 77
SAMPE Journal - November/December 2021 - 78
SAMPE Journal - November/December 2021 - 79
SAMPE Journal - November/December 2021 - 80
SAMPE Journal - November/December 2021 - 81
SAMPE Journal - November/December 2021 - 82
SAMPE Journal - November/December 2021 - 83
SAMPE Journal - November/December 2021 - 84
SAMPE Journal - November/December 2021 - 85
SAMPE Journal - November/December 2021 - 86
SAMPE Journal - November/December 2021 - 87
SAMPE Journal - November/December 2021 - 88
SAMPE Journal - November/December 2021 - 89
SAMPE Journal - November/December 2021 - 90
SAMPE Journal - November/December 2021 - 91
SAMPE Journal - November/December 2021 - 92
SAMPE Journal - November/December 2021 - 93
SAMPE Journal - November/December 2021 - 94
SAMPE Journal - November/December 2021 - 95
SAMPE Journal - November/December 2021 - 96
SAMPE Journal - November/December 2021 - 97
SAMPE Journal - November/December 2021 - 98
SAMPE Journal - November/December 2021 - 99
SAMPE Journal - November/December 2021 - 100
SAMPE Journal - November/December 2021 - 101
SAMPE Journal - November/December 2021 - 102
SAMPE Journal - November/December 2021 - 103
SAMPE Journal - November/December 2021 - 104
SAMPE Journal - November/December 2021 - Cover3
SAMPE Journal - November/December 2021 - Cover4
https://www.nxtbook.com/nxtbooks/sampe/journal_20241112
https://www.nxtbook.com/nxtbooks/sampe/journal_20240910
https://www.nxtbook.com/nxtbooks/sampe/journal_20240708
https://www.nxtbook.com/nxtbooks/sampe/journal_20240506
https://www.nxtbook.com/nxtbooks/sampe/journal_20240304
https://www.nxtbook.com/nxtbooks/sampe/journal_20240102
https://www.nxtbook.com/nxtbooks/sampe/journal_20231112
https://www.nxtbook.com/nxtbooks/sampe/journal_20230910
https://www.nxtbook.com/nxtbooks/sampe/journal_20230708
https://www.nxtbook.com/nxtbooks/sampe/journal_20230506
https://www.nxtbook.com/nxtbooks/sampe/journal_20230304
https://www.nxtbook.com/nxtbooks/sampe/journal_20230102
https://www.nxtbook.com/nxtbooks/sampe/journal_20221112
https://www.nxtbook.com/nxtbooks/sampe/journal_20220910
https://www.nxtbook.com/nxtbooks/sampe/journal_20220708
https://www.nxtbook.com/nxtbooks/sampe/journal_20220506
https://www.nxtbook.com/nxtbooks/sampe/journal_20220304
https://www.nxtbook.com/nxtbooks/sampe/journal_20220102
https://www.nxtbook.com/nxtbooks/sampe/journal_20211112
https://www.nxtbook.com/nxtbooks/sampe/journal_20210910
https://www.nxtbook.com/nxtbooks/sampe/journal_20210708
https://www.nxtbook.com/nxtbooks/sampe/journal_20210506
https://www.nxtbook.com/nxtbooks/sampe/journal_20210304
https://www.nxtbook.com/nxtbooks/sampe/journal_20210102
https://www.nxtbook.com/nxtbooks/sampe/journal_20201112
https://www.nxtbook.com/nxtbooks/sampe/journal_20200910
https://www.nxtbook.com/nxtbooks/sampe/journal_20200708
https://www.nxtbook.com/nxtbooks/sampe/journal_20200506
https://www.nxtbook.com/nxtbooks/sampe/journal_20200304
https://www.nxtbook.com/nxtbooks/sampe/journal_20200102
https://www.nxtbook.com/nxtbooks/sampe/journal_20191112
https://www.nxtbook.com/nxtbooks/sampe/journal_20190910
https://www.nxtbook.com/nxtbooks/sampe/journal_20190708
https://www.nxtbook.com/nxtbooks/sampe/journal_20190506
https://www.nxtbook.com/nxtbooks/sampe/journal_20190304
https://www.nxtbook.com/nxtbooks/sampe/journal_20190102
https://www.nxtbook.com/nxtbooks/sampe/journal_20181112
https://www.nxtbook.com/nxtbooks/sampe/journal_20180910
https://www.nxtbook.com/nxtbooks/sampe/journal_20180708
https://www.nxtbook.com/nxtbooks/sampe/journal_20180506
https://www.nxtbook.com/nxtbooks/sampe/journal_20180304
https://www.nxtbook.com/nxtbooks/sampe/journal_20180102
https://www.nxtbook.com/nxtbooks/sampe/journal_20171112
https://www.nxtbook.com/nxtbooks/sampe/journal_20170910
https://www.nxtbook.com/nxtbooks/sampe/journal_20170708
https://www.nxtbook.com/nxtbooks/sampe/journal_20170506
https://www.nxtbook.com/nxtbooks/sampe/journal_20170304
https://www.nxtbook.com/nxtbooks/sampe/journal_20170102
https://www.nxtbook.com/nxtbooks/sampe/journal_20161112
https://www.nxtbook.com/nxtbooks/sampe/journal_20160910
https://www.nxtbook.com/nxtbooks/sampe/journal_20160708
https://www.nxtbook.com/nxtbooks/sampe/journal_20160506
https://www.nxtbook.com/nxtbooks/sampe/journal_20160304
https://www.nxtbook.com/nxtbooks/sampe/journal_20160102
https://www.nxtbook.com/nxtbooks/sampe/journal_20151112
https://www.nxtbook.com/nxtbooks/sampe/journal_20150910
https://www.nxtbook.com/nxtbooks/sampe/journal_20150708
https://www.nxtbook.com/nxtbooks/sampe/journal_20150506
https://www.nxtbook.com/nxtbooks/sampe/journal_20150304
https://www.nxtbook.com/nxtbooks/sampe/journal_20150102
https://www.nxtbook.com/nxtbooks/sampe/journal_20141112
https://www.nxtbook.com/nxtbooks/sampe/journal_20140910
https://www.nxtbook.com/nxtbooks/sampe/journal_20140708
https://www.nxtbook.com/nxtbooks/sampe/journal_20140506
https://www.nxtbook.com/nxtbooks/sampe/journal_20140304
https://www.nxtbook.com/nxtbooks/sampe/journal_20140102
https://www.nxtbook.com/nxtbooks/sampe/journal_20131112
https://www.nxtbook.com/nxtbooks/sampe/journal_20130910
https://www.nxtbook.com/nxtbooks/sampe/journal_20130708
https://www.nxtbook.com/nxtbooks/sampe/journal_20130506
https://www.nxtbook.com/nxtbooks/sampe/journal_20130304
https://www.nxtbook.com/nxtbooks/sampe/journal_20130102
https://www.nxtbook.com/nxtbooks/sampe/journal_20121112
https://www.nxtbook.com/nxtbooks/sampe/journal_20120910
https://www.nxtbook.com/nxtbooks/sampe/journal_20120708
https://www.nxtbook.com/nxtbooks/sampe/journal_20120506
https://www.nxtbook.com/nxtbooks/sampe/journal_20120304
https://www.nxtbook.com/nxtbooks/sampe/journal_20120102
https://www.nxtbook.com/nxtbooks/sampe/journal_20111112
https://www.nxtbook.com/nxtbooks/sampe/journal_20110910
https://www.nxtbook.com/nxtbooks/sampe/journal_20110708
https://www.nxtbook.com/nxtbooks/sampe/journal_20110506
https://www.nxtbook.com/nxtbooks/sampe/journal_20110304
https://www.nxtbook.com/nxtbooks/sampe/journal_20110102
https://www.nxtbookmedia.com