Adoption of INTAMSYS 3D Printers at CNES

FUNMAT PRO 610HT  is the first INTAMSYS 3D Printer that has been integrated into CNES´s space studies. Upon their positive experience with the printer, FUNMAT PRO 410  has been also added recently to complement their current range of printers within the same laboratory.

CNES Additive Manufacturing Laboratory (photo copyright: CNES and INTAMSYS)

" The impressive ease of use and high print quality of INTAMSYS 3D Printers have greatly contributed to our workflow by meeting our challenges perfectly. Now, we can utilize the entire range of INTAMSYS materials with a click-and-print functionality. Additionally, CADvision, INTAMSYS partner, is highly responsive and provides a great local support, allowing for joint development of improvements to both the machine and software, further enhancing the efficiency and workflow."

Théodore Froissart

Mechanical Integration Manager, The National Centre for Space Studies

Before integrating additive manufacturing, the CNES faced several challenges with traditional manufacturing methods, particularly in qualifying materials for use in clean rooms and satellite testing. Additionally, the long design and manufacturing cycles required to produce a tool was impacting the efficiency. Now with 3D printing, the CNES streamlines this process to a single day, enabling rapid prototyping and design iterations, which ease the process of testing and satellite assembly.

The adoption of the INTAMSYS FUNMAT PRO 610HT has allowed them to use any material they want, such as PolyCarbonate, PEEK and ULTEMTM, crucial for manufacturing complex tools required for satellite testing.

The capabilities of the FUNMAT PRO 610HT have significantly improved the efficiency. Even when using highly specific materials such as PEEK-ESD, developed by the European Space Agency, they can still use the INTAMSYS PEEK profile in INTAMSUITETM NEO (INTAMSYS's slicer) by adjusting a few parameters only. This small adjustment allows the first parts to be ready for printing.

CNES Additive Manufacturing Laboratory (photo copyright: CNES and INTAMSYS)

Case Study: The Stratospheric Drone Structure

The applications that CNES have developed are varied; ranging from simple tooling used in clean rooms for non-structural purposes to large and complex tooling with structural applications used throughout its testing cycle (thermal cycling, shock, vibration, ionizing radiation) to qualify the satellite before launch.

The stratospheric drone structure is one of these complex applications that requires perfect conditions for vacuum chambers and testing environments. The part was printed in one batch using ULTEMTM 9085 material on the FUNMAT PRO 610HT 3D printer. Thanks to the printer´s 610 x 508 x 508 mm build volume and 300°C constant chamber temperature, facilitated by a high-temperature thermal system, the part has been printed perfectly.

The stratospheric drone structure has been designed to be placed under stratospheric balloons. The CNES has had to test the part in different environments, simulating conditions with thin to no atmosphere, to ensure suitability for extreme conditions.

During the testing of the prototype, the design has been qualified by mechanical engineers at the National Centre for Space Studies. While in the same test, the material ULTEMTM 9085 has been also qualified, confirming its compatibility inside vacuum chambers without outgassing, a crucial element for maintaining a good optic performance. Addition to the low outgassing properties, ULTEMTM for aerospace is also crucial due to its exceptional strength-to-weight ratio and high thermal resistance, making it ideal for manufacturing components subjected to extreme conditions in space.

The Stratospheric Drone Structure (photo copyright: CNES and INTAMSYS)

Case Study: Collaboration on the MMX Rover Project

Another interesting project where 3D printing has been used is the MMX Rover, a collaboration between the CNES (the French Space Agency) and JAXA (the Japan Aerospace Exploration Agency) and DLR (the German Aerospace Center). MMX, short for Martian Moons eXploration, is a small rover designed to explore Mars' largest moon, Phobos. In this project, the team utilizes 3D printing for creating, assembling, and testing the rover's parts.

 

MMX Rover Project (photo copyright: CNES)

The role of 3D printing will become even more significant in the near future for spacecraft and the space industry. Looking ahead, the CNES, The National Centre for Space Studies, plans to further enhance its additive manufacturing capabilities and further optimize the use of 3D printing in the space industry.