Laser DED additive manufacturing: Large satellite component (space)

The aim is to replace forged TA6V blanks for large-diameter parts (> 680 mm), which are currently subject to critical lead times exceeding 18 months. In a demanding and highly competitive space context, the goal is to guarantee fully controlled mechanical performance while securing the manufacture of large components that are difficult to source through conventional supply chains, particularly within European production.

IREPA LASER manufactures blanks using powder-fed laser DED, specifically designed for subsequent machining. A process strategy dedicated to large dimensions is developed, combined with numerical simulation to accurately anticipate distortion and secure the final geometry.

Manufacturing large-diameter parts demands a high level of control over distortion phenomena, where the slightest deviation can compromise the entire machining chain. In addition, homogeneous material quality and precisely controlled machining allowances must be guaranteed, an essential condition for securing the final operations. Finally, mechanical performance must be validated without compromise (tensile, fatigue) in a space environment where reliability is non-negotiable.

The solution reduces lead times from over 18 months to just a few weeks. The blanks produced are fully qualified and ready for machining, with validated mechanical properties that meet space industry requirements.