Production and planned in-orbit qualification of a function-integrated, additive manufactured satellite sandwich structure with embedded automotive electronics

Abstract

As part of the Integrated Research Platform for Affordable Satellites project, the German Aerospace Center, the Fraunhofer Institute for Manufacturing Engineering and Automation and the Institute for Space Systems at the University of Stuttgart are investigating new ways of manufacturing satellites more cost-effectively in the future. One of the investigated approaches is a new way of producing structural stalleite elements to save weight, volume and, therefore, costs. This publication presents a functional integrated satellite structure that combines the potentials of additive manufacturing of thermoplastics and miniaturized automotive electronics. The structures’ base is a sandwich with a printed core in which both, the wire harness and automotive micro-electromechanical systems sensors for position and thermal control are integrated. The partial aspects of additive manufacturing and the use of modern automotive electronics were investigated and assesed. In addition, an in-orbit experiment will be presented to evaluate the structure under real conditions.