RF Components Produced Using Large-Scale 3D Printing
Radio frequency (RF) components for Airbus' latest spacecraft: the Eurostar Neo-series relay platform, are being produced by large-scale 3D printing … also known as Additive Layer Manufacturing (ALM).
“This is recognized as the first large-scale deployment of RF components using the ALM process, and it puts us in an industry-leading position for the technology’s application in producing radio frequency components.”
Gareth Penlington, Hotbird Payload Manager.
RF components are at the heart of every telecommunications satellite. A total of 500 radio frequency (RF) components, composed of multi-waveguide blocks and switch assembly networks, have been 3D manufactured by Airbus Defence and Space in Portsmouth, U.K. for two Eurostar Neo spacecraft that will join the in-orbit fleet of Eutelsat, a major provider of satellite communications services.
These two satellites are called Hotbirds. They will be launched in 2021 to reinforce and enhance Eutelsat’s TV broadcasting services over Europe, the Middle East, and North Africa.
Utilizing 3D printing for the Hotbirds provides major labour savings and significantly reduces the number of individual required parts, according to Gareth Penlington, the Hotbird Payload Manager at Airbus.
“This is recognized as the first large-scale deployment of RF components using the ALM process, and it puts us in an industry-leading position for the technology’s application in producing radio frequency components,” said Gareth Penlington, Hotbird Payload Manager.
Airbus’ manufacturing team in Portsmouth developed innovative designs for the Eurostar Neo’s multi-waveguide blocks and switch assembly networks to be 3D printed, taking them from initial concept and patenting through industrialization and the completion of a successful qualification program.
The no. 1 Hotbird satellite’s communications module was transferred earlier this month from Portsmouth to the Airbus Defence and Space facility in Toulouse, France, where the spacecraft’s full build-up will be completed. Assembly of the second Hotbird communications module is now underway in Portsmouth, with its testing to begin in February.
The Eurostar Neo product line is based on a modular concept with a generic service module providing all necessary satellite services and a scalable communications module adapted to specific customer payload accommodation needs.
The Eurostar Neo product is optimized for the use of full electric propulsion and employs state-of-the-art technologies and innovative solutions, along with a versatile but standardised approach to payload equipment layout. Together these increase the competitiveness of the product by reducing costs and development time.
(Image provided with Airbus news release)