Prof.
Stepan Lucyszyn
(Imperial College London)
Over the past three years, a collaboration between Imperial College London and the National Physical Laboratory (NPL) has investigated the RF performance limits of 3D printed X-band and W-band metal-pipe rectangular waveguides (MPRWGs). The metal coated FDM and SLA parts have a measured performance comparable with commercial MPRWGs [1]; demonstrating measured dissipative attenuation levels of ~0.3 dB/m at 10 GHz and 12 dB/m at 110 GHz [2]. Moreover, we have demonstrated the first completely 3D printed X-band MPRWG variable phase shifter [3] and W-band MPRWG 6th-order Chebyshev band pass filter [2] having an unloaded Q-factor of 152 at 107 GHz. These passive components have demonstrated weight savings of 66% at X-band, fast design turnaround times, ultra-low manufacturing costs and complex 3D features. This research has led to a good understanding of the tolerances in fabrication, the frequency each 3D printing technology is limited to (based on surface roughness and print resolution) and the RF material properties. However, further research is required to bring them to flight model readiness. For launch and flight verification, many tests need to be undertaken (vibration analysis, temperature cycling, effects of radiation and atomic oxygen resilience). Cobham Aerospace Communications provides space qualified solutions; for example, compatible coatings to protect against atomic oxygen. Moreover, they have experience in the development of additive manufacturing for space-based applications.
JUSTIFICATION FOR THE CONSIDERATION
Our unique consortium consists of a world-class academic institution having an established Additive Manufacturing Network (Imperial College London) [4], the UK’s primary national laboratory (NPL) for undertaking traceable measurements (mechanical and electrical) at the highest achievable levels of accuracy and with industrial engagement [5], and a formidable aerospace company as a prime supplier of space grade components, equipment and waveguides with 37 years of space heritage and experience (Hyper Technologies SAS, Cobham Aerospace Communications) [6].
Our talk will address additive manufacturing, from a practical technology to meet the harsh environment of space, and discuss the roadmap ahead to find its place in 21st century spacecraft payloads.
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