Additive Spacecraft Panel Structure With Truss Core and Low Thermal Impedance
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Solution Overview
Problem
Conventional spacecraft panel manufacturing methods, particularly using composite sandwich-structure panels, face challenges such as high thermal impedance, high cost, and labor-intensive processes, along with inefficiencies in additive manufacturing due to unsupported features, warping, and cracking.
Innovation Solution
The development of additively manufactured spacecraft panels featuring a truss structure connecting two skins, printed as a single unit without joints or seams, allowing for self-supporting truss members and integrated features like localized reinforcement and thermal management, using materials like laser-sintered metal alloys for improved thermal performance and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite sandwich-structure panels are used, then structural strength is improved, but thermal impedance increases
Solution Approach 1:
The patent merges the core structure and skin panels into a single integrated additively manufactured unit, eliminating the need for separate bonding operations. This integration removes the thermal impedance introduced by adhesive layers while maintaining the sandwich structure's strength benefits through the truss-based core design.
Solution Approach 2:
The patent changes the material parameter from composite materials requiring adhesives to metal alloys that can be directly fused through additive manufacturing. This parameter change eliminates the thermal barrier effect of bonding agents while preserving structural integrity through controlled material deposition and fusion.
2Ease of manufacture
If conventional composite manufacturing methods are used, then structural panels are produced, but manufacturing time and labor cost increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. The core structure, skin panels, and localized reinforcement features are all produced in one continuous build operation, eliminating sequential steps such as tooling removal, ply placement, and multiple curing cycles required by conventional methods.
Solution Approach 2:
The patent performs preliminary design integration during the modeling phase, incorporating all structural features, reinforcement zones, and skin attachments into a single digital model before manufacturing. This preliminary action ensures that no post-processing or assembly operations are needed, significantly reducing manufacturing time.
3Adaptability or versatility
If separate parts are attached for localized features, then functional requirements are met, but expense and labor increase
Solution Approach 1:
The patent merges localized reinforcement features, shielding elements, and skin attachments directly into the core structure during additive manufacturing. These features are integrated as part of the single build process, eliminating the need for separate parts and post-assembly operations while maintaining design flexibility and adaptability.
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 efficient, cost-effective production of lightweight, thermally efficient spacecraft panels with integrated structural features, reducing manufacturing time and eliminating the need for post-processing, while enhancing resistance to thermal loads and environmental stresses.
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)
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
AI summary
A method of additively manufacturing a spacecraft panel includes printing a first skin and a second skin, spaced apart from the first skin. The method further includes printing a first truss structure connecting the first skin to the second skin.