Additive Spacecraft Panel Structure With Truss Core and Integrated Features
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Solution Overview
Problem
Conventional spacecraft panel manufacturing techniques face challenges such as high thermal impedance, labor-intensive processes, and inefficiencies in additive manufacturing, particularly with composite sandwich-structure panels, which are expensive and require post-production modifications for localized features.
Innovation Solution
The method involves additively manufacturing spacecraft panels as single units with two skins connected by a truss structure, allowing for efficient production of lightweight, thermally optimized panels with integrated features like stiffeners and channels, reducing the need for post-processing and separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite sandwich-structure panels are used, then structural strength is improved, but thermal impedance increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations (wrapping, extraction, ply placement, curing stages) into a single additive manufacturing process that creates the complete sandwich panel structure in one continuous build, eliminating the need for separate manufacturing and assembly steps while maintaining structural integrity
Solution Approach 2:
The panel is divided into functional zones with varying core densities - high-density cores in regions requiring structural strength and low-density cores in regions prioritizing thermal management - allowing optimization of both strength and thermal performance in different areas of the same panel
2Strength
If conventional composite sandwich-structure panels are used, then structural strength is improved, but manufacturing time and labor increase
Solution Approach 1:
The additive manufacturing process performs all structural construction, material placement, and feature integration actions during the single printing process itself, rather than requiring preliminary preparation of separate components followed by assembly, thereby eliminating multiple curing stages and touch labor operations
Solution Approach 2:
The additive manufacturing system automatically performs material deposition, layer bonding, and structural formation without requiring external intervention for each operation, eliminating the need for manual ply placement and reducing dependency on skilled touch labor throughout the manufacturing process
3Adaptability or versatility
If separate parts are attached for localized features, then functionality is improved, but manufacturing cost and labor increase
Solution Approach 1:
The patent integrates radiation shielding, reinforcement, and other localized features directly into the panel structure during the additive manufacturing process, merging what would traditionally be separate post-production attachment operations into the single continuous printing process, thereby eliminating additional labor and assembly complexity
4Productivity
If additive manufacturing is used for spacecraft panels, then manufacturing cost and time are reduced, but thermal management performance may be compromised
Solution Approach 1:
The patent implements spatially varying core densities within the panel structure - high-density regions for structural strength and low-density regions for thermal management - allowing each zone to be optimized for its specific function while maintaining overall panel performance
Solution Approach 2:
The additive manufacturing process creates controlled porous or lattice structures in the core regions that facilitate thermal pathways while maintaining structural integrity, allowing heat to conduct through the panel more effectively than solid conventional cores while preserving the lightweight advantage of the sandwich structure
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 enables rapid, cost-effective production of lightweight, thermally efficient spacecraft panels with integrated structural features, improving thermal management and reducing manufacturing time and labor, while allowing for customized designs suitable for space environments.
Implementation Method 1
the granular raw material may include for example thermoplastic polymer, metal powder, metal alloy powder, or ceramic powder, which may be fused using a computer-controlled heat source, such as a scanning laser or scanning electron beam. Exemplary methods include selective laser melting (SLM)
Implementation Method 2
Exemplary methods include selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS)
Implementation Method 3
Exemplary methods include selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modelling (FDM), and electron beam melting (EBM)
Data Source
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AI summary
A method (700) of additively manufacturing a spacecraft panel (100, 200, 300, 400) includes printing (710) a first skin (110, 210, 310, 410) and a second skin (112, 212, 312, 412) spaced from the first skin. The method further includes printing (712) a first truss structure (114, 214, 314, 414) connecting the first skin to the second skin.