In-space and for-space Additive Manufacturing

The recent developments in the manufacturing process and the entry of new privates companies in the space segment are feeding the in-space manufacturing theme. The development of a technology that combines manufacturing and assembly capabilities, practicable in a space environment, is a necessary step to improve safety and to reduce the cost of future space explorations and many other activities. The Additive Manufacturing, between the several technologies tryied in space, is the one that for different reasons, guarantee the highest percentage of success. The operations that can be performed are many: manufacturing and assembly of large-structures, systems’ components, servicing, repair, and many others. Among these, the case of repairing on demand any failed components could dramatically reduce the risks and cost in comparison to the sequence of tasks today needed to achieve the same goal (ground-based manufacturing/assembly and transfer to orbit). The project of thesis here presented, carried out in collaboration with Thales Alenia Space, focuses on topology optimization of an impact shield for protection from collisions with micrometeoroids and orbital debris, which is a thin wall structure, in two different scenarios: (i) additive manufacturing ground-based production and transfer to orbit, (ii) in-space additive manufacturing production. After analyzing the structural performance of the original model, two topological optimizations were carried out whose results are analyzed and presented. A third optimization, of the lattice type, was carried out to propose another optimized configuration that respects the project requirements and the physics of the problem. The aim is to exploit all the potential of Additive Manufacturing via the most recent topology optimization tools. The thesis includes a review of the trends and state of the art of in-space manufacturing technologies with focus on additive manufacturing, presenting the benefits and current challenges to be overcome. In conclusion, possible future developments and studies are proposed.