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Enabling Sensor-Integrated and Sustainable Aerospace Structures Through Additively Manufactured Aluminium Mechanisms

Bernardo Alves1, Rafael Sousa1, Ricardo Coelho1

  • 1University of Coimbra, Centre of Mechanical Engineering, Materials and Processes (CEMMPRE-ARISE), Department of Mechanical Engineering, 3040-248 Coimbra, Portugal.

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Additive manufacturing using material extrusion enables the creation of functional aluminum CubeSat mechanisms. This sustainable process facilitates sensor integration for intelligent aerospace structures.

Keywords:
CubeSatsmetallic additive manufacturingsensor mechanismsspace exploration

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Area of Science:

  • Materials Science
  • Aerospace Engineering
  • Additive Manufacturing

Background:

  • CubeSats are crucial for space exploration, enabling testing of new technologies for efficient satellite systems.
  • Developing integrated, functional components for CubeSats is essential for advancing small satellite capabilities.

Purpose of the Study:

  • To develop and characterize an additively manufactured aluminum mechanism for CubeSat self-functionalization.
  • To evaluate the feasibility of metal additive manufacturing via material extrusion for producing movable satellite components.
  • To establish a foundation for sensor integration and actuation in small satellite systems.

Main Methods:

  • Selected a space-grade AlSi7Mg aluminum alloy and prepared it as a filament for material extrusion.
  • Printed a shrinkage-compensated hinge mechanism, followed by debinding and vacuum sintering.
  • Characterized the sintered components using micro-computed tomography, X-ray diffraction, and dynamic mechanical analysis.

Main Results:

  • Achieved component densification above 85% and an average hardness of 52.2 HV.
  • The sintered hinge mechanism maintained rotational mobility, validating the design and manufacturing approach.
  • Microstructural analysis confirmed the integrity and mechanical behavior of the additively manufactured aluminum parts.

Conclusions:

  • Material extrusion additive manufacturing is a viable, sustainable, and cost-effective method for producing functional aluminum mechanisms for CubeSats.
  • This approach enables the fabrication of lightweight, integrated components suitable for sensor incorporation and actuation.
  • The study demonstrates a pathway for developing intelligent, adaptive aerospace structures for future small satellite subsystems.