Constraint replacement-based design for additive manufacturing of satellite components: Ensuring design manufacturability through tailored test artefacts

Additive manufacturing (AM) is becoming increasingly attractive for aerospace companies due to the fact of its increased ability to allow design freedom and reduce weight. Despite these benefits, AM comes with manufacturing constraints that limit design freedom and reduce the possibility of achieving advanced geometries that can be produced in a cost-efficient manner. To exploit the design freedom offered by AM while ensuring product manufacturability, a model-based design for an additive manufacturing (DfAM) method is presented. The method is based on the premise that lessons learned from testing and prototyping activities can be systematically captured and organized to support early design activities. To enable this outcome, the DfAM method extends a representation often used in early design, a function-means model, with the introduction of a new model construct-manufacturing constraints (Cm). The method was applied to the redesign, manufacturing, and testing of a flow connector for satellite applications. The results of this application-as well as the reflections of industrial practitioners-point to the benefits of the DfAM method in establishing a systematic, cost-efficient way of challenging the general AM design guidelines found in the literature and a means to redefine and update manufacturing constraints for specific design problems.