Page 8 - 3DMP Summer 2022

3D TECH UPDATE 3D Systems-Fleet Space
Technologies Collaboration Yields Satellite Patch Antennas
3D Systems announced a collabora- tion with Fleet Space Technologies lead- ing to the production of RF patch anten- nas for use on Fleet Space Technologies’ Alpha satellite constellation. The report- ed combination of a unique antenna design with expertise provided by 3D Systems’ Application Innovation Group (AIG) allowed realization of a complete additive manufacturing (AM) solution that includes process development and bridge production on the 3D Systems DMP Flex 350 metal-AM machine. The combination reportedly enabled a move from Fleet Space’s existing RF patch design to small-batch production in only three weeks.
Now, Fleet Space Technologies is bringing a DMP Flex 350 machine into service at its Beverley, Australia, head- quarters, allowing the company to pro- vide inhouse production of its patch antennas. The printer will be used to cre- ate RF patch antennas for each of the Alpha satellites operating in a low-Earth- orbit constellation as part of Fleet Space Technologies’ ExoSphere initiative for mining exploration with minimal environ- mental impact.
Fleet Space Technologies’ engineer- ing team designed the antenna to meet size, weight and performance require-
ments while minimizing the need for post-processing, while knowing that only AM could deliver the required geometry. AIG developed print process- es to produce the antenna (pictured) on its DMP Flex 350 printer in two different materials, LaserForm AlSi10Mg and Al6061-RAM2. The unique vacuum chamber architecture of the AM machine, which maintains a low oxygen environment (<25 ppm), was critical, according to AIG officials. This reported- ly greatly reduces argon-gas consump- tion while producing a good surface fin- ish with fine feature detail to minimize antenna signal losses. The DMP Flex 350 also includes 3DXpert software to support each step of the AM workflow from design to post-processing, enabling rapid transition from a 3D model to successfully printed parts.
The team reportedly can achieve pro- duction of 55 RF patch antennas per build on the DMP Flex 350. And, having the AM machine onsite will provide Fleet Space Technologies with the ability to additively manufacture not-previously- available structural components.
“Fleet’s Alpha constellation repre- sents a significant leap forward in our mission to unlock the potential of truly global connectivity, in doing so creat- ing global benefits for applications such as making the search for critical minerals more sustainable and viable,” says Flavia Tata Nardini, founder and CEO of Fleet Space Technologies. “To achieve this, we constantly strive to find more ways to manufacture our technol- ogy to deliver exceptional quality at scale and in a way that is economically viable. Together with 3D Systems’ AIG, we are unlocking the remarkable potential of AM at our world-class facil- ity in Adelaide. This technology will enable our people to create the pro- duction processes that will deliver on Fleet’s ambition to launch more than 140 low-Earth-orbit satellites in the Alpha constellation.”
3D Systems: www.3dsystems.com
NIST Awards Nearly $4 Million to Support Metals-Based AM
The U.S. Department of Commerce’s National Institute of Standards and Tech- nology (NIST) has awarded $3.7 million in grants to help address current and future barriers to widespread adoption of met- als-based AM through measurement sci- ence research.
“The United States can take a leading role in developing the measurements and international standards that will help accelerate adoption of these important 3D-printing technologies,” says Laurie E. Locascio, under secretary of commerce for standards and technology, and NIST director. “To compete globally, we need to invest in programs such as this that bring together our best minds in indus- try, academia and government to solve important technical challenges.
“AM offers advantages such as reduced material waste, lower energy intensity, reduced time-to-market, and just-in-time production that could bol- ster U.S. supply chains,” Locascio adds. “Accelerating the adoption of new measurement methods and standards will help to advance U.S. competitive- ness in this important industry.”
Through its own research and with these grants, NIST is addressing barri- ers to adoption of AM, including meas- urement science to support equiva- lence-based qualification and model-based qualification, the charac- terization of AM materials, and stan- dards to support consistent data exchange/characterizing new advances in AM production systems.
Receiving NIST metals-based AM grants, to be spent over 2 yr.:
• The Research Foundation for the State University of New York (Albany, NY)—$957,706
The goal for this project is to demon- strate an enhanced nondestructive eval- uation technique that can determine key material properties such as oxide thick-
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