Seamless Fluid Module via Additive Monolithic Fabrication

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Solution Overview

Problem

Existing fluid management systems for small spacecraft are prone to leaks, are not compact enough, costly to produce, and have long production times due to the need for multiple fittings and bonding of layers, which can lead to inefficiencies and material mismatches.

Innovation Solution

A seamless fluid storage and transport module is created using additive rapid prototyping processes, such as stereolithography, to form a monolithic structure with integrated plumbing elements that are joined and sealed without bonds, welds, or compression fittings, using materials like WaterShed 11120 that ensure leak-free and smooth surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple fittings and bonded layers are used to assemble fluid management systems, then the systems can be constructed from separate functional components, but the risk of leaks increases and reliability decreases

Engineering Contradiction:

Improveassembly of separate componentsVSAvoidleak-free operation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges multiple separate functional components (tanks, valves, tubing, fittings) into a single monolithic structure fabricated by additive manufacturing. This eliminates the need for assembly through fittings and bonding, thereby eliminating leak paths at joints while maintaining ease of manufacture through integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates the problematic intermediate elements (fittings, bonds, welds, adhesives) from the fluid management system. By removing these potential leak sources entirely and replacing them with a seamless monolithic structure, the system achieves improved reliability without sacrificing manufacturability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If multiple fittings and separate components are used in fluid management systems, then the systems can be assembled from modular parts, but the overall size increases and space efficiency decreases

Engineering Contradiction:

Improvemodular assemblyVSAvoidsystem compactness

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent combines multiple discrete components into a single integrated monolithic structure. This merging eliminates the need for spacing parts apart to accommodate fittings and assembly operations, thereby maximizing space efficiency and minimizing the overall volume occupied by the fluid management system.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If traditional fabrication methods are used to produce fluid management systems, then the systems can be manufactured with conventional processes, but the production time increases and cost increases

Engineering Contradiction:

Improveconventional manufacturing processesVSAvoidproduction speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical fabrication processes (machining, assembly, bonding) with additive manufacturing technology. This substitution enables direct fabrication of complex monolithic structures in a single process, dramatically reducing production time and cost while eliminating the need for conventional assembly operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If tubing is bent to follow permissible paths between components, then the fluid paths can be routed around obstacles, but the bending process becomes difficult, time-consuming, and costly

Engineering Contradiction:

Improvefluid path routingVSAvoidtubing bending process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent integrates fluid path routing directly into the monolithic structure during additive manufacturing. Instead of separately bending tubing to follow permissible paths, the fluid channels are built-in as integral features of the monolithic component, eliminating the difficult and costly tubing bending process while maintaining design flexibility.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution enables the rapid and cost-effective production of leak-free, compact fluid management systems suitable for miniature spacecraft, minimizing the risk of leaks and maximizing space efficiency while ensuring the structural integrity and smoothness required for fluid transport.

Implementation Method 1

depositing successive layers of material upon each other to form a monolithic structure

Methodology Applied

Scientific EffectLayer deposition and fusion: 3D Printing

Data Source

PatentUS8820359B2Seamless fluid storage and transport module

Publication Date: 2014.09.02 AEROSPACE CORP

AI summary

A fluid storage and transport module includes complex plumbing features such as fluid reservoirs, filters, heat exchangers, three-dimensionally routed tubing, valves, mixing chambers, and exit apertures formed in and on a monolithic common bulk material using an additive rapid prototyping process of depositing multiple layers of rapid prototyping materials without welds, adhesives or compression fittings, being made by a method that minimizes leaks, maximizes packing density of the functional components, and increases the plumbing robustness to leaks.