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CRP Technology Makes 3D Printed PocketQube Satellite Deployer for Alba Orbital

First there were the smallsats, and the CubeSats. Now there’s something even smaller to launch into orbit – PocketQubes, a satellite with off-the-shelf electronic components that can fit into your pocket. One eighth the volume of a CubeSat, these tiny space research satellites are 5 cm cubed, with a mass of 250 grams, and while they were only conceived of about ten years ago, interest in them is growing quickly, as it’s becoming more expensive to launch CubeSats into low Earth orbit.

Two years ago, the first PocketQube Standard was issued, and one of the contributors is Scottish high-tech SME Alba Orbital. The company supports this satellite class, as it builds its own PocketQube platforms and provides global companies, space agencies, and universities parts and launches.

Alba Orbital needed to improve the access and manufacturability, and reduce the weight, of its PocketQube satellite deployer, the AlbaPod 2.0, along with adding some new safety features, and is partnering with CRP Technology on the project. The Italian 3D printing company has used its patented Windform TOP-LINE composite materials for aerospace applications in the past, so it was more than up to the task.

3D printed AlbaPod 2.0 on vibration table going through pre-flight certification.

First, CRP analyzed the 2D and 3D files for the deployer, so it could best advise Alba Orbital on which material to use with its Selective Laser Sintering (SLS) process. The high-performance Windform XT 2.0 carbon composite material was chosen, thanks to its increased tensile strength, elongation at break, and tensile modulus.

“As the product needed to withstand a launch to space while containing several satellites, the pod needed to withstand high vibrations, and in the worst scenario, contain any satellite that breaks free internally,” said the Alba Orbital team. “Windform ® XT 2.0’s toughness and strength make it a perfect candidate for this use case.”

3D printed AlbaPods 2.0 in Windform XT 2.0.

Weight reduction is another important design goal for aerospace parts, and the material needs to be flight-approved due to strict degassing rules in space. Windform XT 2.0 has already been approved by major launch providers, making it an easy choice for the launcher.

“Windform® XT 2.0 is a non-outgassing, lightweight fibre reinforced polyamide plastic very similar to Nylon. The material combined with the manufacturing technique allowed us the option to design parts that can not be manufactured with traditional techniques, with thin sections and extremely complex geometry’s, and these parts can be manufactured and delivered in a fraction of the time for a traditional supply chain,” Alba Orbital said.

Fully loaded 3D printed AlbaPod 2.0 for flight – rear cover removed for inspection.

Once Alba Orbital sent the final STP file, CRP Technology quickly created the lightweight AlbaPod v2, a 3D printed deployer for PocketQube-compatible satellites, flight-proven 6P (up to six satellites) and weighing 60% less than the AlbaPod v1.

“The most innovative aspect of the project was the sheer number of components we switched over to Windform ® XT 2.0, not only was the shell redesigned in the material, but also the moving ejection mechanism and door assembly,” Alba Orbital notes.

The 3D printed AlbaPod v2 PocketQube deployer complies with Alba Orbital’s standards, and after performing many tests on the device, Alba Orbital says it has passed the control criteria.

3D printed AlbaPod 2.0 vibration testing.

“This is critical,” they said about the part’s mechanical performance. “Not only does the full assembly need to function correctly to facilitate the deployment of the satellites inside, but must also contain the satellites in the event of catastrophic failure of a payload during the launch as anything breaking free could fatally damage other payloads or the launch vehicle itself. This was tested thoroughly with free masses on vibration tables at extremely high loading and the shell held up phenomenally.

“Additionally weight is a major concern with anything going into space due to the costs associated, utilising Windform ® XT 2.0 allowed us to reduce the mass of a number of major components.”

Integrations began this fall, and six PocketQube satellites were launched into orbit by Alba Orbital in December on the 3D printed AlbaPod v2. The Alba Cluster 2 mission was in orbit for 100 days, and a launch via the 3D printed AlbaPod v2 for the Alba Cluster 3 mission is expected to occur later this year.

“3D printing allows us to rapidly improve design and customise/create bespoke launchers in the future for demanding payloads which may fall outside the Pocketqube standards or require special considerations,” Alba Orbital said.

“It will also allow the fast integration of new release mechanisms allowing us to switch manufacturers comparatively quickly and easily if problems with supply chain arise.”

The first of the two fully loaded AlbaPod 2.0 being attached to the kick stage of Rocket Labs Electron rockets for launch.

The AlbaPod v2 manufacturing experience will be presented this October 8th and 9th at the 4th Annual PocketQube Workshop 2020, held in the Glasgow University Union. The event brings together top innovators from the PocketQube community so they can explore the technology.

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(Images: Courtesy of Alba Orbital)

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CRP Technology releases High Speed Sintering material, Windform P2

CRP Technology, an Italian engineering and 3D printing company, has released its latest additive manufacturing powder for High-Speed Sintering (HSS) known as Windform P2. As the second polymer from the company’s P-Line, the new Windform range of materials for high-speed production-grade 3D printing, P2 is a glass fiber reinforced thermoplastic polyamide material distinguished by increased stiffness. Franco Cevolini, CTO […]

CRP introduces Windform P-LINE range for HSS 3D printing

Italian 3D printing materials manufacturer CRP Technology, has introduced the first product in its P-LINE range of Windform materials for High Speed Sintering (HSS). “Today, I’m very proud to launch Windform P1, the first material from Windform P-Line,” said, Franco Cevolini, VP and CTO at CRP Technology. Cevolini continued, “P stands for Production […] we created […]

CRP Technology Used SLS 3D Printing and Windform XT 2.0 to Make Aircraft Model for Wind Tunnel Testing

The new AW609 wind tunnel model designed for Leonardo HD by Metaltech S.r.l. and 3D printed by CRP Technology

CRP Technology, part of the larger CRP Group, is well-known for its 3D printing applications in the automotive sector, but lest we forget that it is also accomplished in aerospace 3D printing, the company has come out with a new case study about its work creating a new 3D printed wind tunnel model (1:8.5 scale) of the Leonardo TiltRotor AW609 for the Leonardo Helicopter Division (Leonardo HD, formerly known as AgustaWestland).

According to the case study, CRP Technology was able to “highlight the perfect union” between its advanced SLS 3D printing technology and high-performance, composite Windform materials – particularly its Windform XT 2.0, a polyamide-based carbon fiber reinforced composite. Metaltech S.r.l. designed the model.

The goals of Leonardo HD’s project included:

design and manufacture an internal main structure out of aluminum alloy that can easily have new geometries added
complete the work in a very short timetable, but with an extremely high level of commonality and reliability
make components out of materials with high mechanical and aerodynamic characteristics

3D printed aircraft propeller spinners

These goals are why Leonardo HD was referred to CRP Technology – it would be able to meet these goals while 3D printing the external parts for the wind tunnel model, which was designed, manufactured, and assembled in order to complete a series of dedicated low-speed wind tunnel tests. Some of the parts that were 3D printed for the wind tunnel model include nose and cockpit components, fairings, external fuel tanks, rear fuselage, wings, and nacelles.

The level of detail that went into these 3D printed parts “is crucial to the applied loads to be sustainable,” as the wind’s aerodynamic loads in the tunnel are high. So load resistance was one of the more important project aspects, along with maintaining good dimensional tolerances, under load, of large components.

“It is important to remember that the performance of these components affects the final performance of the entire project, especially because the external fairings have to transfer the aerodynamic loads generated by the fuselage to the internal frame,” CRP Technology wrote in the case study.

3D printed tail fairing

The tests needed to cover the standard range of flight attitudes at Leonardo HD’s Michigan wind tunnel facility, in addition to Politecnico di Milano, and varying external geometries were changed during testing, so that technicians would be able to gain a better understanding of “aerodynamic phenomena.”

Today, the CAD-CAM approach is used to design models for wind tunnel testing, before an internal structural frame of aluminum and steel is milled and assembled. Then, 3D printing is used to obtain all external geometries. Because Leonardo HD used CRP Technology’s advanced 3D printing and Windform XT 2.0 material the project was completed much more quickly, with “excellent results and with high-performing mechanical and aerodynamic properties.”

CRP analyzed the dimensional designs that Leonardo HD had sent in order to make the best composite material recommendation: its Windform XT 2.0, with high heat deflection, increased tensile strength and modulus, superior stiffness, and excellent detail reproduction.

“The choice of the Windform XT 2.0 composite material was not casual, all the goals required by Leonardo HD were considered, such as the importance of a short realization time, good mechanical performances and also good dimensional characteristics,” CRP Technology wrote in the case study.

It was necessary to 3D print the single parts separately, as “some components were dimensionally superior to the construction volume of the 3D printing machines,” but CRP Technology was able to complete the project with no time delays. The company used CAD to evaluate the working volume’s functional measures in order to determine which parts to split, and to figure out how to maximize contact surface where structural adhesive would be added to the model.

3D printed aircraft nose and cockpit

It only took four days to 3D print the various parts of the components.

The case study noted, “Different confidential efficiencies, which are an integral part of CRP Technology’s specific know-how, allowed the reduction of the delivery lead time and allowed CRP to minimize the normal tolerances of this technology, and eradicate any potential problem of deformation or out of tolerance.”

The completed model underwent surface finishing, before it was assembled by Metaltech S.r.l. and mounted directly onto a rig assembly, so any small imperfections resulting from single components being put together could be optimized. Thanks to CRP Technology, this step was finished very quickly, and Leonardo HD was able to efficiently flatten the model’s surface and treat it with a special liquid to both prepare for painting and make the model waterproof.

Leonardo HD needed to review the behavior of the aircraft, and so completed a high-speed wind tunnel test campaign, which encompassed speeds Mach 0.2-Mach 0.6, on a new 1:6 scale model at NASA Ames Unitary Plan 11′ x 11′ transonic wind tunnel. The company called on CRP USA, based in North Carolina, to speed up the process, using its partner company’s SLS 3D printing and Windform XT 2.0 composite material to make the external fuselage and some additional components.

3D printed model installed in the 11’x 11’ test section at NASA Ames

While the architecture of the new 3D printed model, which spanned nearly 2 meters, is similar to the original AW609 version, some improvements were made so remote controls could be used for the wing flaperons and elevator surfaces. Additionally, by using four different 6-component strain gauge balances, all the loads were able to act on the complete model, the nacelle, the tail surfaces, and the wing alone.

The model was constructed in such a way as to be mounted in the transonic wind tunnel on a single strut straight sting support system.

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[Images: Leonardo HD]

3D Printing News Briefs: September 29, 2018

We’ve got some 3D printing event news to share with you in today’s 3D Printing News Briefs, along with some business news and a story about a cool 3D printed container. At the TCT Show this week, Additive Industries announced a partnership with Laser Lines, and DEVELOP3D Magazine will soon celebrate product design and metal 3D printing at a live event. CRP Technology has created an updated 3D printed fairing for the Energica Ego Corsa superbike, and employees at the GE Additive Customer Experience Center in Munich made a 3D printed beer krug just in time for Oktoberest.

Additive Industries Partnering with Laser Lines

L-R: Mark Beard, General Manager UK, Additive Industries; Mark Tyrtania, Sales Director, Laser Lines; Daan Kersten, CEO, Additive Industries; and Phil Craxford, Sales Manager, Laser Lines

At the opening of the TCT Show, which took place in Birmingham earlier this week, Additive Industries announced a new partnership with Laser Lines Ltd. in order to speed up its 3D printing presence in the UK and Ireland. Laser Lines is a UK supplier of 3D printers, 3D scanning equipment, lasers, and related accessories, and will work together with Additive Industries to help grow the maturing market in the UK and Ireland for industrial 3D printers. Laser Lines will support Additive Industries in its work to further develop the industrial market for various applications in the aerospace, automotive, machine building, and medical sectors.

“With the recently announced expansion to the UK with a dedicated Process & Application Development Centre, we already acknowledge that the UK & Ireland is an important market that provides great opportunities for industrial companies to enter into industrial metal additive manufacturing,” said Daan Kersten, the CEO of Additive Industries. “With Laser Lines Ltd we add an experienced partner to our fast growing worldwide network that will work with us to identify and manage these opportunities that will contribute to our execution of our accelerated growth.”

DEVELOP3D Magazine Holding Live Event

Each year, DEVELOP3D, a monthly print and digital design journal, holds a live US event all about product design. This year’s DEVELOP3D Live event will be held this coming Tuesday, October 2nd, from 8 am – 6:30 pm at Boston University.

“We have some really fascinating folks coming to celebrate product design in the 21st Century,” Martyn Day from X3D Media, which runs DEVELOP3D, told 3DPrint.com. “We are especially pleased to have Ti Chang from Crave, Tatjana Dzambazova from new metals 3D printing company Velo3D and Olympian, Jon Owen from Team USA Luge.

“Our day is split with MainStage presentations from designers and the industry, together with a track dedicated to Additive Manufacturing, with all the latest in metals 3D printing.”

Tickets are just $50, and include full access to the conference and all 30 exhibitors, plus refreshments, lunch, and drinks at a social mixer. There will be 20 speakers presenting in two separate streams, and topics include CAD, topology optimization, 3D printing, virtual reality, and product development.

3D Printed Fairing for Ego Corsa

Together, Italy-based CRP Group and its subsidiary Energica have been using 3D printing and Windform materials to develop components for electric motorcycles and superbikes for a few years now. In April, the Ego Corsa electric motorcycle completed its third demo lap, and at the last series of road tests before the first edition of the FIM Enel MotoE World Cup, the 2019 2019 Ego Corsa prototype hit the track with a new 3D printed fairing, manufacturing by CRP Technology with its laser sintering technology and Windform XT 2.0 Carbon-fiber reinforced composite material. The 3D printed fairing update has improved the Ego Corsa’s aerodynamics.

“We have had the fairing available in short time. Thanks to the professional 3D printing and CRP Technology’s Windform composite materials, it is possible to modify motorcycle components – even large ones – from one race to the next ones, in order to test different solutions directly on the track,” said the Energica technical staff.

“This fairing is not only more aerodynamic, but it also has a smaller frontal and lateral section. These improvements led to achieve increase in terms of performance and they led to achieve greater manageability in fast corners.

“The Windform XT 2.0 has once again proved to be a high performance composite material. We are very happy how the 3D printed new fairing behaved during the tests.”

GE Additive 3D Prints Metal Beer Stein

Even though the month of October doesn’t start for another few days, Oktoberfest itself officially kicked off last Saturday in Germany. In order to celebrate the occasion, the AddWorks team at the GE Additive Customer Experience Center in Munich, which opened last winter, decided to take another look at the traditional glass beer krug; what we’d call a pitcher or stein in the US.

The unfortunate thing about glass is that it breaks. Obviously, if you’ve enjoyed too much beer at an event like Oktoberfest, the likelihood of breaking your glass drink container goes way up. So AddWorks decided to create a new prototype beer krug, but instead of using glass, they 3D printed it using a combination of stainless steel and titanium…and the result is pretty impressive.

Take a look at the video below, which stars the head of the Munich CEC (Matthew Beaumont), to see the whole process:

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CRP expands applications for SLS Windform 3D printing materials

CRP Group, an Italian industrial group integrating additive manufacturing processes and innovative materials for product development, has expanded its Windform composite materials line for applications within advanced sectors such as aerospace, automotive and motorsport, and Unmanned Aircraft Systems (UAS). Offering a wide range of polyamide-based glass and carbon fiber reinforced materials for SLS 3D printing, […]