Damping-equipped additively manufactured satellite panel

Abstract

To provide a system, an apparatus, and a method for a satellite panel with more effective design having increased damping force in order to realize manufacture of a satellite effectively utilizing a laminated shaping method.SOLUTION: Disclosed is a satellite including a body portion having a laminated shaping wall panel and a communication device connected to the body portion. The wall panel includes a surface plate and a stiffening structure portion extending from a first side of the surface plate. The communication device is configured to send and receive data while the communication device is in space.SELECTED DRAWING: Figure 8

Description

[Background technology]

[0001] Space is a uniquely harsh environment for spacecraft such as satellites. Vibration loads during launch can be particularly harmful to payload equipment, in addition to the risk of damaging radiation and impacts from orbital debris. Many satellite panels are assembled with multiple components fastened together, thereby providing inherent structural damping. However, such designs can be expensive and labor intensive to manufacture.

[0002] Additive manufacturing (AM) is rapidly gaining popularity across many industries as a relatively low-cost, rapid manufacturing method. AM, also known as three-dimensional (3D) printing, can be used to build solid objects from 3D models by additively building the object. AM typically involves adding raw material and then selectively bonding or thermally fusing the raw material to create the desired object. The raw material is typically added in layers, and the thickness of the individual layers can vary depending on the particular technique used.

[0003] Often the raw material is in granular or powder form and is added in layers and then selectively thermally melted by a heat source. Often the top surface of a bed of such material is thermally melted and then the larger workpiece is lowered slightly into the bed itself. A new layer of raw material is then added to the bed and the next layer is thermally melted to the previous layer. The granular raw material may include, for example, thermoplastic polymers, metal powders, metal alloy powders, or ceramic powders, and these granular raw materials may be thermally melted using a computer-controlled heat source, such as a scanning laser or a scanning electron beam. Exemplary methods include selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modeling (FDM), and electron beam melting (EBM), among others. Summary of the Invention [Problem to be solved by the invention]

[0004] Because AM parts are monolithic and have no structural joints, they have lower inherent structural damping. New designs for satellite components, such as structural panels, are needed to make up for this difference and allow AM methods to be used efficiently. [Means for solving the problem]

[0005] The present disclosure provides systems, apparatus, and methods for additively manufactured satellite panels. In some examples, a satellite may include a body portion having an additively manufactured wall panel and a communication device connected to the body portion. The wall panel may include a face plate and a stiffening structure extending from a first side of the face plate. The communication device may be configured to transmit and receive data while in space.

[0006] In some examples, a wall panel for a satellite may include an additively manufactured extension having a first side and a second side, and a stiffening structure on the first side of the extension. The extension may be configured to form a portion of an exterior wall structure of the satellite, and the second side of the extension may be configured to support satellite equipment.

[0007] In some examples, a method of manufacturing a satellite may include printing a wall panel including a face sheet and printing a stiffening structure on the face sheet. The method may further include incorporating the wall panel into an exterior wall structure of the satellite.

[0008] In some examples, a wall panel for a satellite may include an additively manufactured extension that forms part of an exterior wall structure of the satellite. The extension may have a first side and a second side, and the wall panel may further include a damping layer adhered to the first side of the extension. The form, function, and effect may be achieved independently in various examples of the present disclosure or may be combined in yet other examples, further details of which may be understood with reference to the following description and drawings. [Brief description of the drawings]

[0009] [Figure 1] 1 is a schematic diagram of an exemplary satellite. [Diagram 2] FIG. 2 is a block diagram of the satellite of FIG. 1. [Diagram 3] FIG. 1 is an isometric view of an exemplary satellite according to an aspect of the present disclosure. [Figure 4] FIG. 4 is an isometric view of the damping layer of the satellite of FIG. [Diagram 5] FIG. 4 is an isometric top view of an additively manufactured panel of the satellite of FIG. [Figure 6] FIG. 6 is an isometric bottom view of the additively manufactured panel of FIG. [Figure 7] FIG. 4 is an isometric top view of an instrument panel of the satellite of FIG. 3 including the additively manufactured panel and attached damping layer. [Figure 8] FIG. 8 is an enlarged cutaway view of the instrument panel of FIG. [Figure 9] 1 is a flowchart illustrating steps of an exemplary method for additive manufacturing. [Figure 10] FIG. 1 is a schematic diagram of an exemplary additive manufacturing apparatus. [Figure 11] 4 is a flowchart illustrating steps of an exemplary method for manufacturing a satellite in accordance with the present teachings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Various aspects and examples of satellites having additively manufactured panels, as well as related apparatus and methods, are described below and illustrated in the associated drawings. Unless otherwise specified, a satellite according to the present teachings, and / or various components thereof, may, but need not, include at least one of the structures, components, functions, and / or variations described, illustrated, and / or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functions, and / or variations described, illustrated, and / or incorporated herein in connection with the present teachings may be included in other similar devices and methods and may be substituted between the disclosed examples. The following description of various examples is merely exemplary in nature and is not intended to limit the disclosure, its application, or uses in any way. Furthermore, the effects achieved by the examples described below are exemplary in nature, and not all examples achieve the same effects or to the same extent.

[0011] The detailed description includes the following sections: (1) Overview; (2) Examples, Elements, and Alternatives; (3) Exemplary Combinations and Additional Examples; (4) Advantages, Features, and Advantages; and (5) Conclusion. The Examples, Elements, and Alternatives sections are further divided into Sections A through D, with each section numbered accordingly.

[0012] overview In general, an additively manufactured satellite panel according to the present teachings may include a face sheet and stiffeners. Such a panel may also be described as a spacecraft panel, a wall panel, an extension, a wall, and / or a satellite primary structure.

[0013] The faceplate may have an inner surface and an outer surface, such that when the panel is assembled on the satellite, the inner surface of the faceplate faces the interior of the satellite and the outer surface of the faceplate faces the external environment. Depending on the function of the panel, the stiffeners may be disposed on the inner surface of the faceplate and / or the outer surface of the faceplate. For example, if the panel is configured to radiate heat, the stiffeners may be disposed on the inner surface of the faceplate such that the outer surface of the faceplate can be flat to facilitate effective radiation. As another example, if the panel is configured to support equipment, the stiffeners may be disposed on the outer surface of the faceplate so as not to interfere with mounting of the equipment to the inner surface of the faceplate. As another example, the stiffeners may comprise a truss sandwiched between two faceplates.

[0014] The stiffeners may extend from the facesheet and may have any shape effective to provide the facesheet with the desired stiffness. For example, the stiffeners may include web and flange portions that are perpendicular to one another. The stiffeners may form a pattern in the facesheet, such as a grid or array of polygons, including but not limited to triangles and / or squares.

[0015] The panels can be designed for additive manufacturing. For example, all surfaces of the stiffeners may be oriented at an angle of 45 degrees or less relative to the build axis, allowing the stiffeners to be printed without sacrificial support structures, commonly referred to as secondary supports. The facesheets, stiffeners, and / or additional structures may be printed as a single monolithic structure.

[0016] In many examples, the panel may further include a damping layer. The damping layer may be added to the facesheet of the panel and / or the stiffener of the panel following additive manufacturing of the facesheet and additive manufacturing of the stiffener. For example, the damping layer may be bonded to a flange portion of the stiffener.

[0017] The damping layer may include any material suitable for the desired damping force. For example, the damping layer may include a high loss material effective for asymmetric free layer damping. Examples include, but are not limited to, elastomers, rubber, acrylic tape, silicone, and other viscoelastic materials. The properties of the damping layer, such as thickness, stiffness, loss factor, and / or distribution, may be tailored depending on the sinusoidal, shock, and / or random vibrations expected for the panel.

[0018] The panels can be configured to withstand conditions associated with launch into and operation in space For example, the facesheets and stiffeners may comprise a lightweight yet high strength metal such as a laser sintered aluminum alloy, and the damping layer may comprise a heat and radiation resistant elastomer.

[0019] Examples, Components, and Alternatives The following sections describe selected aspects of exemplary satellite panels, and related systems and / or related methods. The examples in these sections are for illustrative purposes and should not be construed as limiting the overall scope of the disclosure. Each section may include one or more separate examples and / or related or associated information, functionality, and / or structure.

[0020] A. Exemplary Satellites and Related Methods Examples disclosed herein may be described in the context of an exemplary satellite launch method (see FIG. 1 ) and in the context of an exemplary satellite 100 (see FIGS. 1 and 2 ). In this example, the method includes three phases: a launch phase 20, a separation phase 30, and a deployment phase 40. The launch phase 20 may include transporting the satellite 100 from a planetary body 120, such as the Earth, to outer space 122, also referred to as space, using a launch vehicle 124. In relation to the Earth, outer space may include the region beyond the Kármán line. The separation phase 30 may include separating the satellite 100 from the launch vehicle 124 once a desired position, orbit, and / or orbit has been achieved. The deployment phase 40 may include preparing the satellite 100 for operations, such as establishing communication between the satellite 100 and a controller on the planetary body 120, extending solar panels or instrument arms, and / or moving to a desired orientation relative to the planetary body. In some examples, the method may further include a design phase, a manufacturing phase, and / or an in-service phase.

[0021] Each of the steps of the launch methodology may be performed or accomplished by a system integrator, a third party, and / or an operator (e.g., a vendor). For purposes of this description, a system integrator may include, but is not limited to, any number of aerospace manufacturers and any number of prime system subcontractors. A third party may include, but is not limited to, any number of vendors, any number of subcontractors, and any number of suppliers. And an operator may be a telecommunications company, a leasing company, a military organization, a service organization, etc. The apparatus and methods shown or described herein may be used during any one or more of the stages of the satellite launch methodology.

[0022] 2, the satellite 100 may include a bus 102 along with a number of satellite systems, a payload 104, and a separation system 106. Examples of the number of systems include one or more of a primary structure 108, a propulsion system 110, a power system 112, a thermal management system 114, a radiation shielding system 116, and a communication system 118. The primary structure 108 may comprise a body portion, a main body portion, a housing portion, a wall structure portion, and / or a frame portion. The payload 104 may include, but is not limited to, satellite instruments, scientific instruments, and / or piggyback communication equipment.

[0023] Each system may include various subsystems, such as controllers, processors, actuators, effectors, motors, generators, etc., depending on the functionality associated with them. Any number of other systems may be included. Although an unmanned satellite example is shown, the principles disclosed herein may be applied to other aerospace vehicles and technologies, such as launch vehicles, space stations, manned spacecraft, and / or interstellar probes.

[0024] B. Exemplary Satellite with Additively Manufactured Instrument Panels 3-8, this section describes an exemplary satellite 200. As previously mentioned, satellite 200 is an example of satellite 100 and includes an instrument panel 220, which is an example of an additively manufactured satellite panel.

[0025] Satellite 200 is generally cubic in shape and may be described as a cube satellite and / or a microsatellite. The satellite includes a body portion 210 that forms the primary structure of the satellite and is an example of the primary structure 108 described in Example A. Body portion 210 is comprised of a number of approximately square wall panels 212 secured together. Body portion 210 may also be described as a housing portion, and wall panels 212 may also be described as exterior wall structures. In the illustrated example, body portion 210 is between approximately 10-30 inches in width.

[0026] Separation system 214, solar panel 216, and plate antenna 218 are attached to body 210. Separation system 214 is an example of separation system 106 described in Example A. Separation system may also be described as a launch vehicle interface ring, where the separation system is configured to serve as the only connection between satellite 200 and the launch vehicle during launch and to facilitate subsequent disconnection of the satellite from the launch vehicle. Solar panel 216 is part of a power system, such as power system 112 described in Example A, and is configured to provide power to satellite 200. Plate antenna 218 is part of a communication system, such as communication system 118 described in Example A, and is configured to interface with the satellite's communications equipment to transmit and receive data while in space.

[0027] Wall panel 212 includes an equipment panel 220 disposed on an opposite side of separation system 214. The equipment panel is configured to support and protect satellite equipment (not shown) during launch and operation. The equipment may include payload equipment, such as sensors, optics, and / or processing systems, and / or may include satellite system equipment, such as electrical components and / or communications equipment. Equipment panel 220 may protect the mounted equipment by damping vibrations resulting from launch of satellite 200 and by shielding the equipment from potentially damaging space radiation.

[0028] In the illustrated example, separation system 214 is a band-based separation system, such as a clamp band or a Motorized Light Band (MLB). Using this separation system, satellite 200 may be attached to a launch vehicle with the central axis of the separation system aligned with the launch vector of the launch vehicle. Equipment panel 220 is located on the opposite side of separation system 214, which allows for the most effective attenuation of axial loads on the equipment panel during launch. For satellites using other separation systems, such as a dispenser-based Quadpack or a Canisterized Satellite Dispenser (CSD), equipment panel 220 may be located in other positions relative to separation system 214.

[0029] Equipment panel 220 is configured and positioned according to the equipment mounted thereon. That is, the design and location of equipment panel 220 may be selected according to the characteristics or requirements of the particular equipment mounted thereon. For example, equipment panel 220 may be positioned on a side of satellite 200 that is expected to face the sun to shield radiation sensitive equipment from the solar wind. As another example, as further described below with reference to FIG. 8, the stiffness and damping characteristics of equipment panel 220 may be tailored according to the resonant frequency of selected payload equipment.

[0030] The instrument panel 220 includes an additively manufactured (AM) panel 222 and a damping layer 224 as shown in FIG. 4. In this example, the damping layer 224 has a grid pattern of equilateral triangles 226 that corresponds to the pattern of the AM panel. Other patterns may be used. As described further below with reference to FIG. 7, the damping layer also includes openings and variations from the grid pattern that match customized features of the additively manufactured panel.

[0031] The damping layer 224 may include any high loss factor material suitable for asymmetric free layer damping. In this example, the damping layer includes a synthetic rubber having a hardness between about 20 and 60 on the Shore A hardness scale. In some examples, the damping layer may include a material having a hardness between about 10 and 100 on the Shore A hardness scale. However, for this example, a hardness between 20 and 60 is preferred because this hardness is soft enough for effective vibration damping while having good structural rigidity. The hardness of the material may be evaluated according to widely recognized testing standards such as ASTM D2240 or ISO 7619. The material or materials of the damping layer 224 may be selected depending on the desired damping characteristics of the layer. For example, a higher hardness may be used to improve damping at the resonant frequency of the payload equipment.

[0032] 5 and 6 show the exterior side 232 and interior side 234 of the AM panel 222, respectively. The AM panel includes a face sheet 230 that is generally square and planar and may also be described as a plate. The face sheet 230 has a first side 233, a second side 235, and four linear outer edges. Extending from the first side 233 of the face sheet, on the exterior side 232 of the panel, is a stiffening structure 236. The majority of the stiffening structure 236 forms a grid of equilateral triangles 240. The face sheet 230 and stiffening structure 236 together may be described as an isogrid or isogrid panel.

[0033] In this example, the surface plate 230 is shaped for a cube satellite. In some examples, the surface plate may have other shapes appropriate for other satellite designs. For example, the surface plate 230 may have a triangular, pentagonal, or irregular shape. The stiffening structures 236 may form any pattern appropriate for the desired stiffness of the AM panel 222. For example, the stiffening structures may form a rectangular grid and / or may form a grid of varying density to allow for varying stiffness in different locations. As will be further described below with reference to FIG. 8, some patterns of the stiffening structures 236 may be preferred as they are more efficient for additive manufacturing.

[0034] The AM panel 222 further includes a number of customized structural configurations 242. The customized configurations may vary depending on the mounting, connectivity, shielding, and / or view factor requirements of the satellite payload and / or satellite operations equipment, as well as launch method, weight constraints, or other related considerations. Additive manufacturing of the panel 222 facilitates these customizations of the configurations, allowing a standardized design to be quickly and inexpensively modified for each satellite produced.

[0035] In the illustrated example, customized structural features 242 include a number of threaded fastener openings 244, fluid exchange connections 246, exterior mounting recesses 248, and star tracker observation window 250. Other possible customized structural features not included in this example include electrical connections, solar panel mounting and / or antenna mounting, and a pattern of openings that match a communications array. Customized structural features 242 may be incorporated into faceplate 230 and / or stiffening structure 236. For example, fluid exchange connections 246 include an opening through faceplate 230 and modifications to stiffening structure 236 to define the location of a recess for receiving a seal.

[0036] Extending from the outer edge of the faceplate are four sidewalls 238. In this example, the sidewalls extend toward the interior of the satellite when the AM panel 222 is assembled to the satellite body. The sidewalls 238 are configured to facilitate connection of the AM panel 222 to other panels of the satellite body. As shown in Figures 5 and 6, the sidewalls have scalloped edges that allow the fastener holes 252 to be located in desired locations relative to the faceplate 230 while minimizing the material and weight of the AM panel 222. In some examples, the AM panel 222 may include other connection configurations in addition to or instead of the sidewalls 238.

[0037] 6, the interior side 234 of the face sheet 230 is flat, except for customized structural features 242. Stiffening structures may be located on the exterior side of the face sheet to facilitate mounting equipment to the interior side 234 and / or to increase available space inside the satellite.

[0038] In the illustrated example, the AM panels 222 comprise a laser sintered aluminum alloy and are printed using direct metal laser sintering (DMLS). In general, the panels may comprise any material having properties such as strength, stiffness, and weight suitable for a satellite and may be manufactured by any effective additive manufacturing method. For example, the AM panels 222 may be manufactured from a polymer using fused deposition modeling (FDM) or from a titanium alloy using electron beam melting (EBM).

[0039] 7 illustrates an instrument panel 220 with a damping layer 224 added to an AM panel 222. In this example, the damping layer 224 is added to and molded to the stiffening structure 236 of the AM panel. That is, the damping layer 224 has the same layout and grid shape as the top surface of the stiffening structure 236. The damping layer 224 can be described as corresponding to and / or substantially covering the stiffening structure 236.

[0040] In some examples, the damping layer 224 may be applied to the face sheet 230, the face sheet and stiffening structure, and / or to a portion of the face sheet and / or to a portion of the stiffening structure. The damping layer may conform to the configuration of the AM panel 222 and / or may have a partially separate or completely separate pattern and / or shape. For example, the damping layer may be applied to a flat face sheet without stiffeners as a plate that substantially covers the side of the face sheet, or as a grid pattern that only partially covers the side of the face sheet. In general, the damping layer 224 may be applied to any structure of the satellite and / or anywhere on the satellite suitable for effective damping. The damping layer 224 may be a single continuous layer, as in the illustrated example, or may comprise two or more separate portions.

[0041] The damping layer 224 may be attached to the AM panel 222 by any effective means. In this example, a synthetic rubber damping layer is molded separately and then bonded to the AM panel using a pressure sensitive adhesive. In some examples, the damping layer 224 material may be applied to the AM panel in a fluid and / or malleable form and then cured and / or dried. Preferably, the damping layer 224 may be bonded, glued, or otherwise attached to the AM panel 222 at all contact points to facilitate effective vibration transmission and damping.

[0042] 8 is a partial cutaway view of the instrument panel 220 showing the stiffening structure 236 in more detail. The stiffening structure 236 may be described as an isogrid flange stiffener and / or a T-beam. In combination with the face sheet 230, the stiffening structure may also be described as forming an I-beam and / or as a flanged isogrid panel. The stiffening structure includes a web portion or webs 260 and a flange portion or cap 262.

[0043] The web 260 extends from the exterior side 232 of the faceplate 230, perpendicular to the faceplate. The cap 262 is centered with the web 260, spaced from the faceplate 230 by the web, and extends parallel to the faceplate. The cap can also be described as extending in two opposite directions from the distal end of the web 260. The damping layer 224 is applied to the top surface of the cap 262.

[0044] In some examples, the stiffening structure 236 may have alternative shapes. For example, the stiffening structure may include only the web 260, or the cap 262 may extend in only one direction from the distal end of the web. The depicted I-beam shape of the stiffening structure is believed to be preferred because it provides stiffness with minimal added weight and also makes it easier to connect the damping layer 224, increasing the damping effect of the layer.

[0045] As shown in Figure 8, the stiffening structure 236 and the faceplate 230 are monolithic; that is, the AM panel 222 is printed as a single unit. The webs 260 and caps 262 are each generally planar and / or plate-like and extend linearly to form a grid of triangles 240. At the intersections of the grid, the webs and caps can be described as forming nodes having circular and / or hexagonal shapes. Both the linear portions and the nodes of the webs and caps may be configured to be printed without sacrificial or secondary supports.

[0046] The AM panel 222 may be printed in a series of layers perpendicular to the build axis 264. The build axis may be defined by the orientation of the AM panel 222 relative to the printer or other additive manufacturing device during printing. The stiffening structure 236 may be configured to be printed without the use of secondary support, and more specifically, may be oriented relative to the build axis 264 such that the stiffening structure can be printed without secondary support. For example, the web 260, cap 262, and the overall pattern of the stiffening structure may form an angle of 45 degrees or less relative to the build axis 264. A grid of equilateral triangles 240 may facilitate this orientation, while other patterns, such as squares, may not have an orientation that meets this angular requirement.

[0047] The dimensions of stiffening structure 236 may be adjusted to achieve a desired stiffness of instrument panel 220 and / or to achieve a desired damping characteristic of damping layer 224. Web 260 has a depth 266 and cap 262 has a width 268. In this example, web depth 266 is between about 0.1-0.3 inches and cap width 268 is between about 0.25-0.75 inches. Each triangle in grid of equilateral triangles 240 has a side length 270. In this example, side length 270 is between about 1-5 inches.

[0048] Varying the cap width 268 can change the moment of inertia of the stiffening structure, thereby changing the stiffness of the instrument panel. Because a damping layer 224 is added to the top surface of the cap 262, changing the moment of inertia of the stiffening structure can also change the damping characteristics of the instrument panel. Varying the triangle side length 270 can change the density of the stiffening structure 236 on the faceplate 230, thereby changing the stiffness of the instrument panel.

[0049] The thickness of instrument panel 220 may also be adjusted to achieve desired panel characteristics. Faceplate 230 has a thickness 272 and damping layer 224 has a thickness 274. In this example, web 260 and cap 262 each have the same thickness as faceplate 230. In some examples, the web and cap may have different thicknesses.

[0050] In this example, the thickness of the face sheet is approximately 0.05 to 0.125 inches. This range provides sufficient radiation shielding for typical satellite equipment without adding unnecessary weight. The appropriate thickness may vary at least in part depending on the material of the face sheet 230. In this example, the thickness 274 of the damping layer is between approximately 0.5 to 5 millimeters. This thickness range provides sufficient vibration damping for typical satellite equipment within the expected range of frequencies and amplitudes. The appropriate thickness may vary at least in part depending on the material of the damping layer 224 and the dimensions of the stiffening structure 236, such as the cap width 268.

[0051] In this example, each of the dimensions depth 266, width 268, length 270, thickness 272, and thickness 274 are constant throughout the equipment panel 220. In some examples, one or more of the dimensions may be varied throughout the panel to achieve localized or targeted changes in the panel's properties. For example, one area of ​​the panel may have a shorter length 270 and a larger width 268, providing additional stiffness needed to support particularly large equipment mounted near that area of ​​the panel. As another example, one area of ​​the panel may have an increased thickness 272 to provide additional shielding for particularly radiation-sensitive equipment.

[0052] C. Exemplary Methods of Additive Manufacturing This section describes steps of an exemplary method 300 for additive manufacturing of a workpiece. See FIG. 9. An embodiment of an exemplary additive manufacturing device shown in FIG. 10 can be utilized in the method steps described below. Where appropriate, references may be made to components and systems that can be used to perform each step. These references are for illustrative purposes and are not intended to limit possible ways to perform particular steps of the method.

[0053] In some examples, the method 300 may be referred to as a method of 3D printing. The terms additive manufacturing and 3D printing may both be understood to include processes in which an object is created by adding material in successive layers. Additive manufacturing may be understood as a broader term that includes 3D printing. In some examples, interchangeable use of the terms additive manufacturing and 3D printing may be appropriate. In this disclosure, printing and / or printing steps may be understood to include creating by any method of additive manufacturing. Examples of additive manufacturing processes include, but are not limited to, material extrusion, powder bed fusion bonding, material jetting, binder jetting, directed energy deposition, liquid bath photopolymerization, and sheet lamination.

[0054] 9 is a flow chart illustrating steps performed in an exemplary method 300, which may not list a complete process or every step of the method. Although various steps of the method 300 are described below and illustrated in FIG. 9, the steps need not all be performed, and in some cases may be performed simultaneously or in a different order than that illustrated.

[0055] At step 310, digital information describing the ordered layers is received. The digital information may be received by a computer controller 412 of an additive manufacturing device 410, as shown in FIG. 10. The additive manufacturing device may be referred to as a printer or fabrication machine. The computer controller 412 may comprise any data processing system that receives the digital design information and controls the functions of the printer 410. The exemplary computer controller shown in FIG. 10 includes a processor 414 for controlling the printer functions and a memory 416 for storing received data.

[0056] The received information may include geometric data and / or design details of a plurality of two-dimensional patterns that make up a layer of a three-dimensional object, where the three-dimensional object is a workpiece 428 to be manufactured. A layer may also be described as a cross section or slice. The multiple layers are ordered, such that the layers may be numbered or planned from the first layer to the last layer.

[0057] A step 312 of the method 300 includes depositing feedstock material on a build platform 418 disposed in a build environment 420 of the printer 410. The build platform may include a support movable along a production axis 422 by a computer controller 412. The build platform may have a plane perpendicular to the production axis 422.

[0058] The feedstock material may be any material, typically a fluid or powder, suitable for additive manufacturing, including, but not limited to, photocurable resins, thermoplastic polymers, plaster, ceramics, and metals. The material may be spread from a feedstock source 424, such as a hopper, tank, or powder bed. For example, aluminum powder may be swept from a powder bed onto the build platform 418 by a brush arm actuated by the computer controller 412.

[0059] The feedstock material may be spread evenly across the build platform 418 or may be deposited in a selected pattern. The depositing may be performed under the control of the computer controller 412. In some examples, the build platform 418 may be submerged in the feedstock material, and the depositing may be accomplished by gravity or fluid pressure. In some examples, a print head 426 connected to a feedstock material source 424 may deposit the feedstock material in a pattern corresponding to a first layer of a plurality of ordered layers.

[0060] In step 314, the raw material is transformed to produce a first layer. In other words, physical changes are induced by the deposited material to realize the first layer as a physical object on the build platform, as directed by the computer controller 412 according to design information describing the first layer of the ordered plurality of layers.

[0061] The material may be acted upon by a print head 426 of the printer 410, which is controlled by a computer controller 412. For example, the print head may include a laser that hardens a photopolymer by exposure to light or sinters a metal powder by exposure to heat. The print head may be instructed by the computer controller 412 to follow a path drawn in the received digital information for the first layer and / or a path calculated by the processor 414 based on the received digital information for the first layer.

[0062] Step 316 includes repositioning the build platform 418. In some examples, the build platform 418 may originate a selected distance from the print head 426. The selected distance may be determined by a procedure performed by the print head. Following fabrication of a layer, the build platform may be repositioned by the computer controller 412 along the fabrication axis 422 away from the print head 426 by the thickness of the layer. That is, the build platform may be moved so that a top surface of the fabricated layer is a selected distance from the print head 426.

[0063] In some examples, the build platform 418 may originate in alignment with another element of the printer 410, such as a feedstock distribution component. Following fabrication of a layer, the build platform may be repositioned along a build axis 422 by the computer controller 412 so that a top surface of the fabricated layer is aligned with other elements of the printer 410. In some examples, in step 316, the print head 426 may be repositioned instead of or in addition to the build platform 418. In some examples, step 316 may be skipped.

[0064] In step 318, a source material is deposited on the layer produced in the previous step of method 300. The source material may be any suitable material and may be deposited in any suitable manner, as described above for step 312. In step 320, the source material is altered to produce the next layer, as described above for step 314.

[0065] Steps 316-320 may be repeated to fabricate each layer of the plurality of layers in the received digital information until the final layer is fabricated. The fabricated first through last layers may then comprise a workpiece 428, as described in the received digital information. The workpiece may be removed from the printer and post-processed, if desired. For example, the workpiece may be removed from the build plate of the build platform and then further finished for detail or smooth surfaces by machining or other methods.

[0066] A workpiece 428 manufactured according to method 300 may have different structural characteristics as compared to a workpiece manufactured according to conventional manufacturing methods, such as machining, molding, and / or assembly. For example, all parts and / or all features of workpiece 428 may be integral and / or monolithic. As another example, workpiece 428 may comprise multiple heat-fused layers of material, each heat-fused layer perpendicular to the build axis of the workpiece. As another example, workpiece 428 may include microstructural anisotropy resulting from the directionality of the manufacturing process.

[0067] D. Exemplary Methods of Satellite Manufacturing This section describes steps of an exemplary method 500 for manufacturing a satellite. See FIG. 11. Aspects of the satellite, panel, and / or additive manufacturing methods and apparatus described above may be utilized in the method steps described below. Where appropriate, references may be made to components and systems that may be used to perform each step. These references are for illustrative purposes and are not intended to limit possible ways to perform particular steps of the method.

[0068] 11 is a flow chart illustrating steps performed in an exemplary method, and may not list a complete process or every step of the method. Although various steps of method 500 are described below and illustrated in FIG. 11, the steps need not all be performed, and in some cases may be performed simultaneously or in a different order than illustrated.

[0069] At step 510, the method includes printing a wall panel. The wall panel can be printed according to any effective additive manufacturing method, such as previously described method 300. The panel can be printed of any material, including but not limited to laser sintered metal or metal alloy.

[0070] Sub-step 512 of step 510 includes printing a face plate. The face plate may be printed according to the build direction of the additive manufacturing device being used. In this example, the face plate may be printed at an angle between about 30-45 degrees relative to the build direction. The thickness of the face plate may be selected depending on the desired radiation shielding or radiation blocking properties of the wall panel. In some examples, the face plate may be square or rectangular in shape. The face plate may include a first side and a second side. In some examples, the first side may include an exterior or external side and the second side may include an interior or internal side.

[0071] Sub-step 514 of step 510 includes printing a stiffening structure. The stiffening structure may be printed on a first side of the face sheet. The stiffening structure may also be described as being printed on a first side of the wall panel. The stiffening structure may comprise a regular repeating grid or a regular repeating lattice extending from the face sheet and / or may comprise a local shape and a local form. In some examples, at least a portion of the stiffening structure may form a grid of equilateral triangles. In such examples, the wall panel may be described as an isogrid.

[0072] Sub-step 516 of step 514 includes printing a web portion and a flange portion of a stiffening structure. The web portion may extend from the face plate and the flange portion may extend from a distal end of the web portion. The stiffening structure may be described as a T-beam or as forming an I-beam with the face plate. The dimensions of the stiffening structure, such as the width of the flange portion, may be selected depending on the desired stiffness of the wall panel and the moment of inertia of the stiffening structure.

[0073] The stiffening structure may be printed simultaneously with the faceplate. In other words, sub-steps 512 and 514 may be performed simultaneously. Each layer of material deposited during printing may include a portion of the faceplate and a portion of the stiffening structure. The faceplate and stiffening structure may be printed as a single monolithic structure. In other words, the faceplate and stiffening structure may be printed together to form a panel of printed material with no joints or seams.

[0074] Method 500 may not include post-processing the printed wall panels, i.e., the panels may be designed and printed such that smoothing out surface roughness, removing sacrificial support material, and / or machining additional features is not required.

[0075] At step 518, the method includes adding a damping layer to the wall panel. The added layer may include any high loss factor material suitable for free layer damping. Examples include, but are not limited to, elastomers, natural or synthetic rubber, acrylic tape, silicone, and other viscoelastic materials. The properties of the damping layer, such as thickness, stiffness, loss factor, and / or distribution, may be selected depending on the desired damping characteristics of the wall panel. For example, the hardness of the damping layer may be selected depending on the resonant frequency of the equipment to be mounted to the wall panel.

[0076] The damping layer may be applied in any effective manner. In this example, sub-step 520 of step 518 includes adhesively bonding the damping layer to the wall panel. The damping layer may be molded, stamped, rolled, cut, and / or otherwise formed and then bonded to the wall panel with a pressure sensitive adhesive. In some examples, the damping layer may be sprayed, painted, rolled, and / or otherwise formed directly onto the wall panel and then dried or cured in place.

[0077] The damping layer can be applied to some or all of the wall panel. For example, the damping layer can be applied only to a first side of the wall panel, or can be applied in a continuous sheet, pattern, and / or multiple discontinuous portions. In this example, sub-step 522 of step 518 includes applying the damping layer to a flange portion of the stiffening structure of the wall panel. The damping layer can substantially cover a top surface of the flange portion or an outer surface of the flange portion.

[0078] Step 524 of method 500 includes incorporating the wall panel into an exterior wall structure of the satellite. The exterior wall structure may also be described as a body portion of the satellite and / or a primary structure portion of the satellite. Incorporating the wall panel into the exterior wall structure may include connecting the wall panel to one or more additional panels. The wall panels may be connected along an edge or side region, may be connected flush, or may be connected at an angle relative to another panel. The panels may be connected by any effective means. For example, the panels may be welded and / or bolted to adjacent panels. In some examples, step 510 may include printed connections, such as brackets or fastener openings, that facilitate incorporating the wall panel into the exterior wall structure.

[0079] Illustrative Combinations and Additional Examples This section describes additional aspects and configurations of satellites and additively manufactured panels, which are not intended to be limiting as a series of paragraphs, and some or all of which may be designated alphabetically for clarity and efficiency. Each of these paragraphs may be combined in any suitable manner with one or more of the other paragraphs and / or with disclosure from elsewhere in this application. Some of the following paragraphs explicitly refer to and further qualify other paragraphs, providing some examples of suitable combinations, without limitation to these examples.

[0080] Furthermore, the present disclosure includes the following examples, whereby the scope of protection is provided by the claims.

[0081] A0. A body having an additively manufactured wall panel including a face sheet and a stiffening structure extending from a first side of the face sheet; A communications device attached to the body that will send and receive data while in space A satellite comprising:

[0082] A1. A satellite of A0, whose surface plates and stiffening structures form an isogrid.

[0083] A2. An A0 or A1 satellite with the first side of the faceplate on the exterior of the satellite.

[0084] A3. Any of the satellites A0 to A2, in which the first side of the surface plate is inside the satellite.

[0085] A4. Any of the satellites A0 to A3, wherein the stiffening structure includes a web portion and a flange portion.

[0086] A5. A satellite of A4 further comprising a damping layer bonded to the flange portion of the stiffening structure.

[0087] A6. A satellite of A5, where the damping layer comprises a viscoelastic material.

[0088] A7. A satellite of A5 or A6, where the stiffening structure and damping layer form a grid of equilateral triangles on the first side of the wall panel.

[0089] A8. Any of the satellites A0-A7 further comprising a damping layer adhered to the wall panel.

[0090] A9. A satellite of A8, where the attenuation layer is on the outside of the satellite.

[0091] A10. A satellite, A8 or A9, where the attenuating layer is inside the satellite.

[0092] A11. Any of the satellites A0-A10 in which the stiffening structure is sandwiched between the surface and an additional surface.

[0093] A12. A satellite of A11, whose stiffening structure is a truss.

[0094] B0. An additively manufactured extension forming part of an exterior structure of a satellite, the extension having a first side and a second side; a stiffening structure on a first side of the extension, the second side of the extension being configured to support satellite equipment; 13. A wall panel for a satellite comprising:

[0095] B1. A wall panel of B0, in which the extension and stiffening structure are part of a single monolithic structure.

[0096] B2. Wall panel of B1, with extension and stiffening structure made of laser sintered metal alloy.

[0097] B3. A wall panel of any of B0 to B2, in which the extension and stiffening structure form an isogrid.

[0098] B4. A wall panel according to any one of B0 to B3, wherein the stiffening structure has a web portion and a flange portion.

[0099] B5. Wall panel of B4 further comprising a damping layer bonded to the flange portion of the stiffening structure.

[0100] B6. A wall panel of B4, wherein a second side of the wall panel is configured to support mounting of equipment.

[0101] B7. The wall panel of any of B0-B6, further comprising a damping layer attached to the extension.

[0102] B8. Wall panel of B7 with a damping layer bonded to the first side of the extension.

[0103] C0. Printing a wall panel including a surface plate and printing a stiffening structure on the surface plate; incorporating the wall panel into an exterior wall structure of the satellite; A method for manufacturing a satellite, comprising:

[0104] C1. Method C0, in which the surface plate and stiffening structure form an isogrid.

[0105] C2. The method of C0 or C1, wherein the stiffening structure includes a web portion and a flange portion.

[0106] C3. The method of C2, further comprising the step of adding a damping layer to the flange portion of the stiffening structure.

[0107] C4. Any of methods C0-C3, wherein the face sheet has an inner surface and an outer surface, and the stiffening structure extends from the outer surface of the face sheet.

[0108] D0. An additively manufactured extension forming part of an exterior structure of a satellite, the extension having a first side and a second side; a damping layer bonded to a first side of the extension; A wall panel for a satellite comprising:

[0109] D1. A wall panel of D0 configured with a first side facing space.

[0110] D2. A wall panel of D0 or D1 having a second side configured to support equipment within a satellite enclosure.

[0111] D3. Any of the wall panels D0 to D2, in which the first side of the extension includes a stiffening structure.

[0112] D4. Wall panel of D3 with isogrid extension.

[0113] D5. Wall panel of D3 or D4, the stiffening structure including a web portion and a flange portion.

[0114] D6. Wall panel of D5 where the damping layer is attached to the flange of the stiffening structure.

[0115] D7. A wall panel of any of D0 to D6, the extension of which is made of laser sintered metal alloy.

[0116] D8. Wall panel of D7 with extension constructed of aluminium.

[0117] D9. Any wall panel from D0 to D8, in which the damping layer consists of a viscoelastic material.

[0118] D10. Any wall panel D0-D9, the extension of which comprises a monolithic sandwich structure.

[0119] D11. A wall panel of any of D0 through D10, wherein the extension includes a face plate having a thickness sufficient to block at least 0.5 megarads of radiation per year from outside the enclosed space.

[0120] E0. An additively manufactured extension forming part of an exterior structure of a satellite, the extension having a first side and a second side; a damping layer on a first side of the extension; 13. A wall panel for a satellite comprising:

[0121] E1. Wall panel of E0, where the damping layer consists of a viscoelastic material.

[0122] E2. A wall panel of E0 or E1 with a damping layer adhesively bonded to the first side of the extension.

[0123] E3. Any wall panel from E0 to E2, in which the damping layer has a thickness of 0.2 to 5.0 mm.

[0124] E4. Any wall panel from E0 to E3, in which the damping layer has a thickness of 0.5 to 2.0 millimeters.

[0125] E5. Any wall panel E0-E4, the extension of which is made of laser sintered metal alloy.

[0126] E6. Wall panel of E5 with extensions constructed in aluminium.

[0127] E7. Any wall panel E0-E6, where the damping layer forms a grid of equilateral triangles.

[0128] E8. Any of the wall panels E0 to E7, wherein the extension has a stiffening structure on a first side of the extension.

[0129] E9. The wall panel of E8, wherein the stiffening structure has a web portion and a flange portion, and the damping layer is attached to the flange portion of the stiffening structure.

[0130] F0. Printing a wall panel including a face sheet having a first side and a second side; adding a damping layer to the wall panel; incorporating the wall panel into an exterior wall structure of the satellite; A method for manufacturing a satellite, comprising:

[0131] F1. Method F0, in which the damping layer is made of a viscoelastic material.

[0132] F2. The method of F0 or F1, wherein the attaching step includes adhesively bonding the damping layer to the wall panel.

[0133] F3. Any of methods F0-F2, wherein the damping layer has a thickness between 0.2 and 5.0 millimeters.

[0134] F4. Any of methods F0 to F3, wherein the damping layer has a thickness between 0.5 and 2.0 millimeters.

[0135] F5. Any of the methods F0-F4, wherein the damping layer covers a majority of the first side of the faceplate.

[0136] F6. Any of the methods F0-F5, wherein the damping layer forms a grid of equilateral triangles on the first side of the faceplate.

[0137] F7. Any of the methods of F0-F6 further comprising printing a stiffening structure on the first side of the face sheet.

[0138] F8. A method as in F7, wherein a damping layer is added to the stiffening structure.

[0139] F9. A method as in F7 or F8, wherein the skin and stiffening structure form an isogrid.

[0140] F10. Any of the methods of F7-F9, wherein the stiffening structure has a web portion and a flange portion, and the damping layer is applied to the flange portion of the stiffening structure.

[0141] Effects, Forms, and Benefits The different examples of additively manufactured satellite panels described herein provide several advantages over known solutions for designing and manufacturing satellites. For example, the illustrative examples described herein enable rapid, on-demand manufacturing of panels.

[0142] Additionally, among other advantages, the illustrative examples described herein reduce manufacturing cycle times, including reducing the number of manufacturing steps, touch-handling time, and post-manufacturing testing.

[0143] Additionally, as another advantage, the illustrative examples described herein facilitate effectively protecting sensitive equipment from launch-related vibration loads while reducing the integral damping forces of the additively manufactured panels.

[0144] Additionally, among other benefits, the illustrative examples described herein enable the use of strong, stiff, and lightweight panels to effectively protect sensitive equipment from potentially damaging space radiation.

[0145] Additionally, as another advantage, the illustrative examples described herein allow for a high level of customization and localized design, including in the form of localized reinforcement or radiation spot shielding, access points, stiffness adjustments, integrated payload specific equipment mountings, tailoring to expected vibration loads and expected equipment tolerances, and the like.

[0146] There are no known systems or devices capable of performing these functions, particularly for metal alloy panels that are high strength and lightweight. Thus, the illustrative examples described herein are particularly useful for satellite structural panels. However, not all examples described herein are equally effective or to the same degree.

[0147] conclusion The foregoing disclosure may include multiple separate examples having independent utility. Each of these examples is disclosed in its preferred form, but the specific examples disclosed and illustrated herein should not be considered in a limiting sense, as numerous variations are possible. To the extent that section headings are used in this disclosure, such headings are for organizational purposes only. The subject matter of the present disclosure includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. The following claims specifically teach certain combinations and subcombinations that are deemed novel and non-obvious. Other combinations and subcombinations of features, functions, elements, and / or properties may be claimed in applications claiming priority from this or related applications. Such claims are considered to be within the subject matter of the present disclosure, whether broader, narrower, equal, or different in scope than the original claims. [Explanation of symbols]

[0148] 20 Launch phase, 30 Separation phase, 40 Deployment phase, 100 Satellite, 102 Bus, 104 Payload, 106 Separation system, 108 Primary structure, 110 Propulsion system, 112 Power system, 114 Thermal management system, 116 Radiation shielding system, 118 Communication system, 120 Planetary body, 122 Space, 124 Launch vehicle, 200 Satellite, 210 Main body, 212 Wall panel, 214 Separation system, 216 Solar panel, 218 Plate antenna, 220 Instrument panel, 222 AM panel, 224 Damping layer, 226 Equilateral triangle, 230 Surface plate, 232 Exterior side, 233, 235 Side, 234 Interior side, 236 Stiffening structure, 238 Side wall, 240 Triangle, 242 Structural form, 244 Threaded fastener openings, 246 Fluid exchange connections, 248 Outer mounting recesses, 250 Star tracker observation window, 252 Fastener holes, 260 Web, 262 Cap, 264 Build axis, 266 Depth, 268 Cap width, 272, 274 Thickness, 410 Printer, additive manufacturing device, 412 Computer controller, 414 Processor, 416 Memory, 418 Build platform, 420 Build environment, 422 Manufacturing axis, 424 Raw material source, 426 Print head, 428 Workpiece

Claims

1. a body portion (108, 210) having an additively manufactured wall panel (220) including a face sheet (230) and a stiffening structure (236) extending from a first side (233) of the face sheet; a communications system (118, 218) connected to said body portion for transmitting and receiving data while in space; A satellite (100, 200) comprising: the stiffening structure (236) includes a web portion (260) and a flange portion (262); The satellite (100, 200), further comprising a damping layer (224) bonded to the flange portion (262) of the stiffening structure (236).

2. The satellite (100, 200) of claim 1, wherein said face sheet (230) and said stiffening structure (236) form an isogrid.

3. The satellite (100, 200) of claim 1, wherein the first side (233) of the face plate (230) is external to the satellite.

4. The satellite (100, 200) of any one of claims 1 to 3, wherein the surface plate (230) and the stiffening structure (236) are part of a single monolithic structure, and the surface plate has a thickness sufficient to block at least 0.5 megarads of radiation per year from outside an enclosed volume.

5. The satellite (100, 200) of claim 4, wherein said face sheet (230) and said stiffening structure (236) are constructed from a laser sintered metal alloy.

6. The satellite (100, 200) of any preceding claim, further comprising a damping layer (224) adhered to said wall panel (220), said damping layer having a thickness between 0.2 and 5.0 millimeters.

7. The satellite (100, 200) of any one of claims 1 to 6, wherein the damping layer (224) is external to the satellite.

8. The satellite (100, 200) according to any one of the preceding claims, wherein the damping layer (224) comprises a viscoelastic material.

9. The satellite (100, 200) according to any one of the preceding claims, wherein the stiffening structure (236) and the damping layer (224) form a grid of equilateral triangles (240) on the first side (233) of the wall panel (220).

10. Printing (510) a wall panel (220) including a face sheet (230) and printing a stiffening structure (236) on said face sheet; incorporating (524) the wall panel into an exterior wall structure (108, 210) of a satellite (100, 200); A method (500) for manufacturing a satellite, comprising: the stiffening structure (236) includes a web portion (260) and a flange portion (262); A method (500) for manufacturing a satellite, the method (500) further comprising the step (518) of adding a damping layer (224) to the flange portion (262) of the stiffening structure (236).

11. 11. The method (500) of claim 10, wherein the face sheet (230) has an inner surface (235) and an outer surface (233), and the stiffening structure (236) extends from the outer surface of the face sheet.

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