Laser DED additive manufacturing: Lightweight, optimised satellite interface (space)

Designing a TA6V structural interface for the space sector requires taking advantage of the freedom offered by additive manufacturing while meeting very strict mechanical and mass constraints. The aim is to reduce the number of assemblies and overall mass, while securing performance and drastically cutting lead times.

IREPA LASER carried out a complete redesign of the part using a design approach tailored to powder-fed laser DED, thereby limiting machining operations. Topology optimisation and finite element simulation validation made it possible to integrate several previously separate functions into a single-piece architecture.

The project required a complete redesign, integrating the constraints of the additive manufacturing process from the earliest stage. Validation of a consolidated architecture made it possible to replace several sub-assemblies while guaranteeing mechanical performance in a demanding space environment.

The solution achieved a 15 % weight reduction of the part and significantly simplified assembly. Mechanical performance was validated through testing, with a major reduction in manufacturing lead time, from 18 months to 3 months compared with a forged blank.