3D Printed Spacecraft Antenna Reflectors
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Solution Overview
Problem
Existing spacecraft antenna reflectors face challenges in achieving large apertures for increased efficiency while maintaining a compact form for launch and minimizing weight to withstand launch forces.
Innovation Solution
The technology enables the 3D printing of large concave reflectors in space using a small 3D printer assembly, allowing for larger antenna apertures without the need for a large launch vehicle space and reducing the weight by avoiding the necessity to withstand launch forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If larger reflectors are used to capture more RF radiation and improve efficiency, then communication efficiency is improved, but weight increases and difficulty to stow for launch increases
Solution Approach 1:
The reflector is manufactured in space before the spacecraft reaches its operational position, eliminating the need to transport a large, heavy reflector from Earth. The 3D printing process begins after launch, allowing the reflector to be created in situ at its full operational size.
Solution Approach 2:
The reflector structure evolves dynamically during the spacecraft mission, growing from a small initial structure to its full operational size through continuous 3D printing. This dynamic growth allows the system to achieve large aperture without the static constraints of pre-launch assembly.
2Productivity
If larger reflectors are used to capture more RF radiation and improve efficiency, then communication efficiency is improved, but difficulty to stow for launch increases
Solution Approach 1:
The reflector manufacturing process is initiated after the spacecraft reaches orbit, eliminating the need to allocate significant launch vehicle volume for reflector storage. Only the compact 3D printing apparatus and materials need to be launched, not the full-sized reflector.
Solution Approach 2:
The reflector is built in a different operational dimension (in-orbit manufacturing) rather than being constrained by the three-dimensional space available during launch. This temporal and spatial separation allows the reflector to achieve its full size without occupying launch vehicle volume.
3Strength
If reflectors are designed to withstand launch forces, then structural strength is improved, but weight increases
Solution Approach 1:
The reflector is manufactured after the spacecraft reaches orbit, eliminating exposure to harsh launch forces entirely. The structure can be optimized for its operational environment in space rather than being over-engineered to withstand Earth launch conditions.
Solution Approach 2:
The reflector structure can have varying local properties optimized for its specific function in space, rather than requiring uniform high strength throughout to withstand launch. Critical areas can be reinforced while non-critical areas use lighter materials or thinner sections.
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
This approach allows for the creation of lightweight, large-aperture reflectors that enhance communication efficiency without the constraints of launch vehicle dimensions and forces, facilitating more effective spacecraft communication systems.
Implementation Method 1
a 3D printer head configured to form a concave spiral structure around a hub by depositing material
Implementation Method 2
a reflector positioned to reflect RF signals to/from a feed assembly. The reflector may be in the form of a dish that has a concave surface to focus received RF radiation towards the feed assembly
Data Source
AI summary
An example apparatus includes a first 3D printer head configured to form a spiral structure around a hub and a second 3D printer head configured to form a boom extending between the second 3D printer head and the hub. The apparatus further includes one or more actuators coupled to the first 3D printer head and the second 3D printer head to control a distance between the first 3D printer head and the second 3D printer head.