Function modelling and constraints replacement to support design for additive manufacturing of satellite components

Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.