CNES 创新使用 INTAMSYS 3D 打印机 | 卫星组装的增材制造解决方案

法国国家太空研究中心（CNES，Centre National d’Études Spatiales）是法国航天局，成立于 1961 年，隶属于政府机构。该机构负责开展空间研究、设计并执行航天任务，同时推动欧洲以及全球范围内的航天技术发展。

多年来，CNES 在卫星装配阶段就已使用 3D 打印及相关增材制造技术，并不断探索创新手段。

CNES 的“实现与集成”（Realization and Integration，RI）部门专注于卫星的组装与测试，同时开发用于装配和测试环节的工具与设施（例如：集成框架、多用途小车、吊装装置等），以便在发射前于 CNES 洁净室环境中进行操作。这些洁净室维持严格的控制条件，以确保卫星部件在稳定环境下作业。

为制造这些集成装置与工具（如集成框架、多用途小车等），CNES 越来越多地采用基于创新聚合物的 FFF 3D 打印方式。早在 2014 年，CNES 便使用单材料 3D 打印机进行生产；随着要制造的部件数量与复杂度不断增加，其增材制造实验室也随之迅速发展。

远铸智能 3D 打印机在易用性和打印质量方面表现非常出色，完美地解决了我们的挑战，并极大提升了我们的工作流程。现在，我们可以非常便捷地使用整套远铸智能材料，实现一键打印。此外，作为远铸智能的合作伙伴，CADvision 反应迅速，并提供了优质的本地支持，使我们能够共同改进设备与软件，从而进一步提升效率与工作流程。

Theodore Froissart
法国国家太空研究中心机械集成主管

在引入增材制造之前，CNES 在传统制造方式下面临多项挑战，尤其是在洁净室和卫星测试中对材料进行资质验证。此外，为生产一件工装所需的设计与制造周期过长，也影响了整体效率。如今，通过 3D 打印，CNES 将这一流程大幅压缩至一天之内，实现快速原型开发与设计迭代，从而显著简化卫星测试与装配流程。

采用远铸智能 FUNMAT PRO 610HT 后，CNES 可以使用任意所需材料，例如 PC、PEEK 和 ULTEM™，这些材料对于制造复杂的卫星测试工装至关重要。

FUNMAT PRO 610HT 的能力大幅提高了效率。即便使用诸如欧洲航天局开发的 PEEK-ESD 这类高度特殊的材料，他们仍可在远铸智能切片软件 INTAMSUITE™ NEO 中基于远铸智能 PEEK 参数配置，仅做少量调整即可进行打印，使首批部件迅速进入制造阶段。

CNES 开发的应用范围十分广泛，从洁净室中用于非结构用途的简单工装，到用于卫星全流程测试（热循环、冲击、振动、电离辐射）以完成发射前资格验证的大型结构性工装，均涵盖在内。

其中，平流层无人机结构便是一个高度复杂的案例，它要求在真空环境和极端测试条件下具备完美表现。该部件采用 ULTEM™ 9085 材料，在 FUNMAT PRO 610HT 3D 打印机上一体成型完成。依托打印机 610 × 508 × 508 mm 的大体积成型空间，以及由高温热系统支持的 300°C 恒温腔体，该部件得到了理想的打印质量。

该平流层无人机结构被设计用于安装在平流层气球下方。为确保其适用于极端环境，CNES 对其进行了不同环境条件下的测试，以模拟稀薄或近乎真空的大气环境。

在原型测试过程中，该结构设计通过了法国国家太空研究中心机械工程师的验证；与此同时，ULTEM™ 9085 材料也完成了认证，确认其可在真空舱内使用且不会发生析气现象——这一点对于维持光学性能具有决定性意义。

除了极低的析气特性外，适用于航天的 ULTEM™ 材料还具备卓越的强度重量比与高耐热性，因此非常适用于制造需要承受极端条件的航天部件。

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.

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

3D PRINTER

FUNMAT PRO 410
COST-EFFECTIVE

Print Larger, Print More
OPEN

Open-Sourced Filaments

3D PRINTER

FUNMAT HT
COST EFFICIENCY

Lower Cost, Shorter Lead Times
MATERIAL SUPERIORITY

Versatile INTAM™ Polymers

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.

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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法国国家航天中心（CNES）在卫星装配中创新使用远铸智能 3D 打印机

CNES 采用远铸智能 3D 打印设备

案例研究：平流层无人机结构

案例研究：MMX 探测车项目合作

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

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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