3D-Printed Foldable Satellite Panels With Integrated Hinges
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Solution Overview
Problem
Conventional satellite production methods are time-consuming and costly due to the use of numerous structural parts and fasteners, leading to increased mass and limited geometric complexity, while additive manufacturing technologies face challenges with production time and raw material usage.
Innovation Solution
A satellite system comprising foldable panels produced by additive manufacturing, with integrated hinges allowing panels to rotate and overlap, reducing the need for additional fasteners and enabling compact production and assembly, using materials like Ti-6Al-4V or Al—Si-10Mg, and methods such as selective laser melting or fused deposition modeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional production methods (machining, sheet metal, composite processes) are used, then satellite platforms require use of a large number of structural parts and fasteners, but this extends production time and increases satellite mass
Solution Approach 1:
The patent combines multiple separate components (panels and hinges) into a single integrated structure produced by additive manufacturing. This merging eliminates the need for separate fasteners and assembly operations, directly reducing production time while maintaining ease of manufacture through the additive process.
Solution Approach 2:
The additive manufacturing process serves multiple functions simultaneously: it produces both the panel structures and the hinge mechanisms in a single operation, and creates integrated connection features without requiring separate fastening components. This multi-functionality resolves the contradiction by improving productivity without sacrificing ease of manufacture.
2Ease of manufacture
If conventional production methods are used, then satellite platforms require use of a large number of structural parts and fasteners, but this increases satellite mass in direct proportion
Solution Approach 1:
By merging the panel and hinge into a single additive-manufactured component, the patent eliminates multiple separate fasteners and structural parts. This integration directly reduces satellite mass while maintaining ease of manufacture through the additive process, which can produce complex geometries without additional assembly hardware.
Solution Approach 2:
The invention extracts and eliminates the need for separate fasteners and auxiliary assembly elements by integrating their functions directly into the additive-manufactured panel structure. This extraction of unnecessary components reduces satellite mass while preserving ease of manufacture.
3Productivity
If additive manufacturing is used to produce complex geometries and integrated parts, then production time and cost are reduced, but size of the final part and amount of raw powder material used are the main limiting factors
Solution Approach 1:
The patent employs nested positioning where multiple panels are arranged in overlapping configurations during additive manufacturing, with panels placed in nested or overlapping orientations. This nesting approach maximizes the utilization of the build volume, reducing the overall size required for the final part while minimizing raw powder material consumption.
Solution Approach 2:
The invention utilizes three-dimensional positioning and orientation of panels during additive manufacturing, arranging them in spatial configurations that optimize material usage. By leveraging dimensional arrangements rather than simple linear stacking, the patent reduces both the final part size and the amount of raw powder material required while maintaining high production efficiency.
4Ease of operation
If cube satellite is produced openly with hinges and folded into cube form, then panels can be kept stable during assembly, but this requires much more area and reduces production efficiency by increasing production costs
Solution Approach 1:
The patent merges the panel and hinge into a single integrated component produced by additive manufacturing. This eliminates the need for separate folding and assembly operations, significantly improving production efficiency while maintaining ease of operation through the inherent stability of the integrated structure.
Solution Approach 2:
The hinges and folding mechanisms are pre-integrated into the panel structure during additive manufacturing, rather than being assembled separately afterward. This preliminary action of incorporating all necessary features during production eliminates subsequent assembly steps, improving production efficiency while preserving ease of operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient production in smaller areas, reduces assembly time, decreases satellite mass, and lowers production costs by minimizing the use of fasteners and enabling faster assembly and transportation.
Implementation Method 1
selective laser melting
Implementation Method 2
fused deposition modeling
Data Source
AI summary
A satellite system has a table on which additive manufacturing is carried out. A plurality of panels are produced by the additive manufacturing method and surround a plurality of satellite elements such as payload, satellite electronic circuits and mechanisms such that they protect the satellite elements from space conditions, wherein satellite elements are mounted on the panels in a removable manner. At least one hinge allows the panels to rotate around each other, and produced by additive manufacturing method in an integrated manner with the panels.