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Category: DLR

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AMPFORS

AMPFORS
2nd Place 2017 Challenge by the DLR Space Administration Label

Additive Manufacturing for Space Using High-Performance Polymers

AMPFORS

AMPFORS (Additive Manufacturing of Polymer Parts for Space) is seeking to replace the metal structural components used for space applications with lightweight polymer parts. These parts are produced by means of additive manufacturing, which is also known as 3 D printing. To compensate for their lower mechanical stability compared to meta 1, the polymer components are then outfoted with a metallic layer to form a “sandwich” composite. AMPFORS plans to use both the high-performance polymer PEEK and the less expensive material polyamide (PA). In addition to the space sector, this project’s key markets include aircraft manufacturing, mechanical engineering, tool-making, and medical equipment production.

Benefits:

  • Makes satellite structures up to 20% lighter and up to 50% less expensive
  • lncorporation of metal coatings improve the mechanical, electrical, and thermal properties of polymers; also prevents the emission of water and monomers
  • Additive Manufacturing process speeds up component design and production
Andreas Dietz

Fraunhofer IST
Brunswick, Germany
Dr Andreas Dietz
www.ist.fraunhofer.de
ondreos.dietz@ist.frounhofer.de

Fraunhofer
OHB
AM_Rauch
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Wall#E

Wall#E Image
2017 overall winner
2017 DLR Winner

Wall#E: Fibre-Reinforced Spacecraft Walls for Storing Energy

Wall#E Image

The idea behind Wall#E involves integrating energy storage functions into the support structures of spacecraft, which will significantly reduce the mass and volume of satellites without sacrificing performance. To this end, Wall#E utilises fibre-reinforced structures (which enjoy more and more popularity in aerospace engineering) infiltrated with innovative solid-state battery materials. While this project’s initial focus is on satellites, the underlying concept can easily be adapted to launch systems, space stations, and ground-based e-mobility applications.

Benefits:

  • Reduced satellite mass
  • Simpler, more compact constructions
  • Lower costs of development/launch
Enrico Stoll

TU Braunschweig – Institute of Space Systems
Brunswick, Germany
Prof Dr-Ing Enrico Stoll
www.space-systems.eu
e.stoll@tu-bs.de

Logo
Logo
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Infused Thermal Solutions

infused thermal solutions
overall winner

Infused Thermal Solutions

infused thermal solutions

Technical components in space are often exposed to fluctuating temperatures, which can lead to degraded performances or reduced lifetimes. Infused Thermal Solutions (ITS) is an innovative concept to passively stabilize the temperature of thermo-elastic spacecraft components. This idea combines known concepts of phase change materials (PCM) with modern manufacturing techniques (3D printing). The phase change materials are embedded inside custom-printed, double-walled component structures, offering a standalone solution.

Benefits:

  • Temperature stabilisation
  • Reduced thermo-elastic deformations
  • Increased component lifetimes
  • Creation of complex lightweight “bionic” structures
  • Cost reduction
  • Technology transfer (spin-off), e.g. in the automotive industry
finalist

Fachhochschule Aachen
Aachen, Germany
Prof Dr Markus Czupalla
www.fh-aachen.de
czupalla@fh-aachen.de

infused thermal solutions
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SUMSENS – Structure-Borne Ultrasonic Multi-Hop Sensor Network for the Temperature Monitoring of Satellites

sumsens
3rd place

SUMSENS – Structure-Borne Ultrasonic Multi-Hop Sensor Network for the Temperature Monitoring of Satellites

sumsens

The mechanical and thermal integrity of spacecraft will be crucial for future space missions lasting months, years, or even longer. Traditionally, wired sensors are used to measure all relevant parameters. SUMSENS offers the integration of a holistic wireless sensor network using the satellite structure itself for communication, in order to provide in-situ monitoring of the mechanical and thermal subsystem status. The SUMSENS sensor network consists of smart temperature sensor nodes, communicating among themselves via structure-borne ultrasonic waves. The core of each sensor node is a microcontroller platform providing all required data operations.
SUMSENS integrates Augmented Reality (AR) to support visual system integration, monitoring and maintenance. The technology can be transferred from space to ground transportation.

Benefits:

  • Wireless sensor network instead of heavy, space-consuming network infrastructure consisting of cable clutter
  • Cost reduction due to flexible installation, easy expandability, low energy consumption and reduction of communication traffic
  • Reliable, fail-safe network architectures
  • Modularity, allowing flexible installation
  • High-level structural integration
finalist picture

Fraunhofer LBF
Darmstadt, Germany
Dr Torsten Bartel
www.lbf.fraunhofer.de
torsten.bartel@lbf.fraunhofer.de

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Silent Running – Intrinsic Structural Vibration Reduction for Carrier Rockets Using Metamaterials

silent running
2nd place

Silent Running – Intrinsic Structural Vibration Reduction for Carrier Rockets Using Metamaterials

silent running

When launching and flying a rocket, vibrations must be reduced to such an extent that they do not cause damage to the payload and structure. In the “Silent Running” project, MT Aerospace and Fraunhofer LBF are using carbon-fibre-reinforced plastics (CFRP) with metamaterials, in order to reduce the vibrations that affect on the payload and structure during acceleration. Metamaterials combine the benefits of active and passive vibration reduction and are used, in the automotive industry, amongst others. “Silent Running” specifically targets to minimise vibrations in the upper stages of future Ariane carrier rockets. The innovative vibration dampers should be integrated into the load-bearing structure of the carrier rockets, so that the heavy damping elements conventionally used are no longer required.

Benefits:

  • Efficient rocket stages and complex payloads with longer service lives by minimising vibrations in the stage structures
  • Efficient rocket stages and complex payloads with longer service lives by minimising vibrations in the stage structures
  • Transporting of satellites with effective payloads and thus improved payload/cost ratio per launch
  • Spin-off into the automotive, aerospace and shipping industries
Sara Perfetto

Fraunhofer LBF
Darmstadt, Germany
Sara Perfetto
www.lbf.fraunhofer.de
sara.perfetto@lbf.fraunhofer.de

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Multifunctional lightweight structures for satellites

Multifunctional lightweight structures for satellites
3rd Place 2016 Challenge by the DLR Space Administration Label

Multifunctional lightweight structures for satellites

Multifunctional lightweight structures for satellites

Conventional satellite design separately considers functional, structural and protective requirements. Subsystems are not integrated into the primary structure, but applied at a later production stage.

  • Project aim: disruptive innovation in satellite design
  • Integration of functions into load-carrying structural parts (communication, thermal management, vibration control, diagnosis)
  • Concurrent optimisation of structural and functional properties with respect to mass and production processes
  • Validation by a demonstrator

 Fraunhofer Institute for Structural Durability and System Reliability LBF
Dr Dirk Mayer
dirk.mayer@lbf.fraunholer.de

RWfH Aachen University
Dr Athanasios Dafnis
dafnis@sla.rwth-aachen.de

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OCULUS – Optical Coatings for Ultra Lightweight Robust Spacecraft Structures

OCULUS - Optical Coatings for Ultra Lightweight Robust Spacecraft Structures
2nd Place 2016 Challenge by the DLR Space Administration Label

OCULUS – Optical Coatings for Ultra Lightweight Robust Spacecraft Structures

OCULUS - Optical Coatings for Ultra Lightweight Robust Spacecraft Structures

Low weight as well as high durability and accuracy for mirrors of space telescopes? New material solutions have great potential to make it happen! The objective is to combine innovative production processes of carbon-fibre-reinforced plastic (CFRP) structures and reflective coatings. By this means, lightweight optical mirrors can be developed for aerospace applications (e.g. remote sensing and astronomy) that exhibit versatile advantages over conventional mirrors:

  • Thermal stability (no cooling necessary)
  • 80% to 90% weight reduction
  • Modularisation in production (large quantities using one tool)
  • Smart coatings enable multifunctional surfaces
  • Process transferable to mechanical engineering industry

Prof Enrico Stoll
e.stoll@tu-bs.de

INVENT GmbH
Stefan Linke
stefan.linke@invent-gmbh.de

Fraunhofer IST
Dr. Andreas Dietz
andreas.dietz@ist.fraunhofer.de

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Skith: Skip the Harness (Harnessless Satellite)

SKITH
Winner 2016 Challenge by the DLR Space Administration Label
Overall Winner 2016 Label

Skith: Skip the Harness (Harnessless Satellite)

SKITH

The harness for satellites has been necessary so far but also costly, heavy and a major risk factor. Skith aims to create the first wireless satellite, by using short range, high speed real time miniature radio communication links.
By combining modular and fault-tolerant software with ultra-wideband technology from industry 4.0, a robust and adaptable system will be created.

Skith is aiming at:

  • Reducing the costs of integration and launches of satellites
  • Increasing the dependability of machines, especially of satellites and aircrafts
  • Increasing the Flexibility of control systems
  • Making the board computer independent from input/output (10) devices
Universität Würzburg

lnformatics 8 – Aerospace Information Technology

Prof Sergio Montenegro
montenegro@informatik.uni-wuerzburg.de

Tobias Mikschl
tobias.mikschl@uni-wuerzburg.de

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