New applications of rapid prototyping and rapid manufacturing (RP/RM) technologies for space instrumentation

In the frame of a research project, CRIF, KUL and CSL have investigated the possibility to use rapid prototyping and rapid manufacturing (RP/RM) techniques during space instrument development. Rapid prototyping and rapid manufacturing terms gather several techniques with the common baseline that parts are built layer by layer, starting from a CAD model. These techniques imply powder, paste or liquid and are applicable to polymers, ceramics and metals. In a first step, the major advantages of these techniques have been presented to Belgian industries implied in the space sector and, as a result of the discussions, development goals for the project have been identified. Several types of use have also been pointed, from demonstration mock-up to real space hardware. In parallel to technical developments, several case studies and tests have been performed. The case studies have shown that the rapid manufacturing allows complex geometries to be created. A drastic decrease of the number of separate parts and bolted junctions ease the predictability of the mechanical and thermal behaviour and limit the risk of imperfect junction. As a result of the project, a guidelines document has been issued to give as much information as possible on how to perform a space instrument design using the advantages of RP/RM techniques.