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CNES Uses INTAMSYS 3D Printers Innovatively in Satellite Assembly

3D Printing in Space Studies

The CNES, The National Centre for Space Studies, is the French Space Agency, a governmental organisation founded in 1961. It conducts research, designs, and operates space missions, and promotes the development of space technologies within Europe and internationally.

The organisation has been utilizing 3D printing, along with innovative additive manufacturing techniques, during the phases of satellite assembly for many years now.

The Realization and Integration (RI) department of the CNES specializes in assembly and testing satellites, as well as developing tools and means to facilitate the assembly and testing in CNES's clean rooms before launch (e.g. integration frames, multi-purpose trolley, lifting device, etc.). These clean rooms maintain precise conditions to ensure a stable environment for the satellite components.

To produce these tools and means such as integration frames, multi-purpose trolley, the use of FFF 3D Printing method with innovative polymer materials has been increasingly employed at the CNES. Initially starting with a single-material printer in 2014, the CNES's additive manufacturing laboratory has rapidly evolved due to the number and complexity of the parts to be produced.

Adoption of INTAMSYS 3D Printers at CNES

FUNMAT PRO 610HT is the first INTAMSYS 3D Printer that has been integrated into CNES´s space studies. Upon their positive experience with the printer, FUNMAT PRO 410 has been also added recently to complement their current range of printers within the same laboratory.

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CNES Additive Manufacturing Laboratory (photo copyright: CNES and INTAMSYS)

The impressive ease of use and high print quality of INTAMSYS 3D Printers have greatly contributed to our workflow by meeting our challenges perfectly. Now, we can utilize the entire range of INTAMSYS materials with a click-and-print functionality. Additionally, CADvision, INTAMSYS partner, is highly responsive and provides a great local support, allowing for joint development of improvements to both the machine and software, further enhancing the efficiency and workflow.

Theodore Froissart
Mechanical Integration Manager, The National Centre for Space Studies

Before integrating additive manufacturing, the CNES faced several challenges with traditional manufacturing methods, particularly in qualifying materials for use in clean rooms and satellite testing. Additionally, the long design and manufacturing cycles required to produce a tool was impacting the efficiency. Now with 3D printing, the CNES streamlines this process to a single day, enabling rapid prototyping and design iterations, which ease the process of testing and satellite assembly.

The adoption of the INTAMSYS FUNMAT PRO 610HT has allowed them to use any material they want, such as PolyCarbonate, PEEK and ULTEMTM, crucial for manufacturing complex tools required for satellite testing.

The capabilities of the FUNMAT PRO 610HT have significantly improved the efficiency. Even when using highly specific materials such as PEEK-ESD, developed by the European Space Agency, they can still use the INTAMSYS PEEK profile in INTAMSUITETM NEO (INTAMSYS's slicer) by adjusting a few parameters only. This small adjustment allows the first parts to be ready for printing.

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CNES Additive Manufacturing Laboratory (photo copyright: CNES and INTAMSYS)

Case Study: The Stratospheric Drone Structure

The applications that CNES have developed are varied; ranging from simple tooling used in clean rooms for non-structural purposes to large and complex tooling with structural applications used throughout its testing cycle (thermal cycling, shock, vibration, ionizing radiation) to qualify the satellite before launch.

The stratospheric drone structure is one of these complex applications that requires perfect conditions for vacuum chambers and testing environments. The part was printed in one batch using ULTEMTM 9085 material on the FUNMAT PRO 610HT 3D printer. Thanks to the printer´s 610 x 508 x 508 mm build volume and 300°C constant chamber temperature, facilitated by a high-temperature thermal system, the part has been printed perfectly.

The stratospheric drone structure has been designed to be placed under stratospheric balloons. The CNES has had to test the part in different environments, simulating conditions with thin to no atmosphere, to ensure suitability for extreme conditions.

During the testing of the prototype, the design has been qualified by mechanical engineers at the National Centre for Space Studies. While in the same test, the material ULTEMTM 9085 has been also qualified, confirming its compatibility inside vacuum chambers without outgassing, a crucial element for maintaining a good optic performance. Addition to the low outgassing properties, ULTEMTM for aerospace is also crucial due to its exceptional strength-to-weight ratio and high thermal resistance, making it ideal for manufacturing components subjected to extreme conditions in space.

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The Stratospheric Drone Structure (photo copyright: CNES and INTAMSYS)

Case Study: Collaboration on the MMX Rover Project

Another interesting project where 3D printing has been used is the MMX Rover, a collaboration between the CNES (the French Space Agency) and JAXA (the Japan Aerospace Exploration Agency) and DLR (the German Aerospace Center). MMX, short for Martian Moons eXploration, is a small rover designed to explore Mars' largest moon, Phobos. In this project, the team utilizes 3D printing for creating, assembling, and testing the rover's parts.

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MMX Rover Project (photo copyright: CNES)

The role of 3D printing will become even more significant in the near future for spacecraft and the space industry. Looking ahead, the CNES, The National Centre for Space Studies, plans to further enhance its additive manufacturing capabilities and further optimize the use of 3D printing in the space industry.

About CNES:

CNES is the French Space Agency, a governmental organisation founded in 1961. As programme-focused agency and centre of technical expertise, CNES is responsible for shaping and implementing France’s space policy within the framework of international cooperation, particularly within Europe. For more information, visit https://cnes.fr/en.

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After thorough research and benchmarking, WEERG chose INTAMSYS as their supplier. The INTAMSYS FUNMAT PRO 410 met all their requirements with features like a heated chamber, dual heated nozzles, and a heated filament chamber.

INTAMSYS offered one single solution that got it all:

  • A robust printer with a sleek aesthetic finish, heated chamber, dual heated nozzles, and heated filament chamber.
  • Free and user-friendly software with incorporated printing settings (Click and Print experience) for a wide range of materials (from PA12-CF to PEEK).
  • Reliable support, and most importantly for WEERG, honesty and a true partnership.
WEERG also appreciated the user-friendly software with incorporated printing settings and the reliable support from INTAMSYS.

They went for INTAMSYS and received their FUNMAT PRO 610HT in June 2021. Since the purchase of the printer, they have printed many prototypes, some end-use parts, and from time to time jigs/fixtures and tooling parts.

As the printer has a high chamber temperature (up to 300°C), it also means that all temperatures in between are covered too. 4D Concepts has printed out parts of many plastic types; from PLA, ABS, PC, to PAEK, PEEK, PEI 9085/1010.

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4D Concepts – prototype of a temperature-resistant pulley made of glass-fiber reinforced PEEK (PEEK-GF).

 

We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector.

Alex Di Maglie
Managing Director,  4D Concepts

We were looking for printers that can print high-performance materials and run 24/7 on our production floor. INTAMSYS offered a robust printer, a nice aesthetic finish, and a true partnership.

Matteo
Founder & CEO, WEERG

The application of high-end filaments made of high-performance plastics such as PEI is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of PEI 9085.
 

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The INTAMSYS FUNMAT PRO 410 has been a performant and reliable tool since day one. It allows us to process high-performance polymers that enable our customers to innovate with them in highly loaded, thermally challenging, and metal replacement applications. It gives us the confidence that is needed to print 24/7 unattended with long print jobs of 100+ hours. It redefines what can be achieved with FDM technology.

Fabio Trotti
3D R&D Manager, WEERG

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Our Solution

INTAMSYS has sponsored the GreenTeam with a FUNMAT HT 3D printer, INTAM™ filaments, and consultation services. The 3D printed parts from INTAMSYS are used in various subsystems of the car, including the battery system, braking system, and power electronics.

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Tank Holder

The tank holder is a new part in this year´s racing car. The part is printed on the FUNMAT PRO 610HT with the material choice of ABS. For the driverless disciplines, the team uses pressurized air to activate the brakes in an emergency. This year, they changed the concept of how pressurized air is stored, which required a new mounting solution. The tank holder is designed to solve this challenge.

Tank holder
Flap Ribs (2)

Flap Ribs

Other 3D printed parts, using the FUNMAT PRO 610HT and PC material, are the flap ribs that play a crucial role in the construction of the car’s side wing. These ribs are glued into the carbon-fiber shells and incorporate threaded inserts for attaching the wing to the chassis.

While the team has used these ribs for years, they have redesigned for this season to accommodate changes in the aerodynamic shape of the wings. Using INTAMSUITE™ NEO and the 3D printing technology, they conducted topology optimization to achieve the lightest possible geometry, resulting in an organic shape that would not be possible to manufacture by milling.


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