CNES Uses INTAMSYS 3D Printers Innovatively in Satellite Assembly

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.

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 ULTEM^TM 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 ULTEM^TM 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, ULTEM^TM 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.

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.

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.