Airbus Defence and Space to use 3D printed components on Eurostar E3000 satellites

Airbus Defence and Space in the UK said the first 3D printed component has been created for its Eurostar E3000 telecommunications satellites.

The first space-qualified 3D printed component was developed as part of a R&D programme under National Space Technology Programme through Innovate UK and the UK Space Agency.

Newbury, England-based additive manufacturing company, 3T RPD produced the additive layer manufactured (ALM) bracket for Airbus Defence and Space.

The structural bracket is a single piece laser melted part designed to mount the telemetry and telecommand (TMTC) antennas onto the satellite.

The new component is said to be 40% stiffer and weigh 35% less compared to a previous bracket, which comprises four parts and 44 rivets. It does not result in waste generated by conventional machining, Airbus Defence and Space said.

The ALM bracket completed flight qualification testing, and is ready to be equipped on an upcoming satellite.

Airbus Defence and Space senior spacecraft structures engineer for the project Amy Glover said: "Through developing and proving the design and manufacturing process, which significantly reduces the testing required, we can now look at what other opportunities there are for ALM components that will be lighter and quicker to manufacture."

The company plans to produce ALM waveguides, heat pipes, propulsion components, secondary structures and tanks.

Innovate UK Space head Tim Just said: "Space is a vital and growing sector of the UK economy worth over £11bn and employing directly 34,000 people and supporting a further 72,000 jobs.

"We at Innovate UK are determined to maximise the opportunities for companies big and small to build a UK space supply chain and build the new jobs of tomorrow."

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Image: The 3D printed-structural bracket will be used on Eurostar E3000 telecommunications satellites manufactured from aluminium alloy. Photo: courtesy of Airbus Defence and Space Ltd.