In-Orbit Additive Manufacturing for Large Space Structures
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Solution Overview
Problem
Current 3D printing technologies are inadequate for manufacturing large objects in space due to environmental challenges such as extreme radiation, temperature fluctuations, and microgravity, which disrupt the printing process and result in defects, and existing antennas are too small due to structural limitations imposed by spacecraft payload dimensions, leading to performance limitations and increased launch costs.
Innovation Solution
A controllable additive manufacturing system on a spacecraft that uses a 3D printer to fabricate objects, including antennas, in orbit by controlling the spacecraft's pose relative to astronomical bodies, incorporating sensors and a command system to manage environmental conditions, allowing for the use of high-temperature resistant materials and metals, and enabling the creation of larger structures than those feasible within the spacecraft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antennas are manufactured on the ground and folded for launch, then they can be transported to space, but the folding mechanisms are complicated and prone to failure
Solution Approach 1:
The patent applies preliminary action by pre-positioning the antenna in a compact configuration within the spacecraft, then using a simple deployment mechanism to unfold it to its operational shape in orbit, avoiding complex folding mechanisms while ensuring reliable deployment through pre-planned positioning and controlled activation
Solution Approach 2:
The antenna is segmented into multiple deployable panels or elements that can be stored compactly during launch and then unfolded or extended to form the complete operational structure in space, reducing deployment complexity while maintaining reliability through modular design
2Productivity
If the antenna size is increased to improve communication performance, then data rate and beam focus improve, but the antenna cannot fit within the spacecraft payload compartment
Solution Approach 1:
The patent transitions from three-dimensional compact storage to two-dimensional planar deployment, allowing the antenna to fit within the spacecraft's payload volume during launch and then expand to a large operational surface area in orbit, effectively using the space dimension to resolve the volume-performance contradiction
Solution Approach 2:
The antenna is designed with dynamic deployability, transitioning from a compact static configuration during launch to a large extended configuration in orbit, allowing the structure to adapt its volume to match the operational requirements while fitting within launch constraints
3Ease of manufacture
If conventional 3D printing is used in space, then manufacturing capability is provided, but environmental factors cause printing defects and process disruption
Solution Approach 1:
The patent creates a controlled inert environment around the 3D printing apparatus, using barriers or enclosures to shield the printing process from harmful space environmental factors such as radiation and extreme temperature fluctuations, thereby maintaining manufacturing precision while enabling in-orbit production
Solution Approach 2:
An intermediary controlled environment or protective enclosure is introduced between the space environment and the 3D printing process, acting as a buffer that filters harmful environmental factors while allowing the printing operation to proceed with normal precision and quality
Data Source
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AI summary
Spacecraft including a spacecraft bus (100). An additive manufacturing system of the spacecraft bus including at least one extruder (110A, 110B) for delivering feedstock to print an object outside of the spacecraft bus (100). A sensor for determining a pose of the spacecraft bus relative to an astronomical body. At least one processor in communication with the additive manufacturing system and the sensor, controls an operation of the additive manufacturing system as a function of the pose of the spacecraft bus, to manufacture the object outside of the spacecraft bus.