Thales Alenia Space and 3D Systems Prove Viability of Direct Metal Printing

3D Systems’ On Demand Manufacturing team delivers critical 3D printed metal satellite parts that are 25% lighter and ready in half the time of traditional production techniques

The Breakdown:

CHALLENGE

Produce Lighter-Weight Brackets for Telecommunications Satellite

Each bracket mounted on the antenna required a unique topologically optimized design for lower weight without sacrificing strength.

SOLUTION

Thales Alenia and 3D Systems Use DMP for Better Bracket

Direct-metal-printed brackets are 25-percent lighter, have a better stiffness-to-weight ratio, and can be manufactured in half the time it would take with a traditional process.

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Reigniting the F-1 Apollo Engine with Geomagic 3D Scanning Solutions

Recreating the massive F1-Apollo rocket in a complete 3D assembly took 3D scanning, Geomagic Wrap and just 4 months of work to complete

“It was evident from the start that 3D scanning and imaging were a requirement of this job.”

The Breakdown:

CHALLENGE

Reconnecting Design With As-Built for NASA’s Apollo F-1 Rocket Engine

Although some blueprints of the original F-1 engine design exist, the basic drawings that were available revealed a disconnect between the original design and as-built results.

SOLUTION

ShapeFidelity Uses Geomagic Software to Accurately Reverse Engineer the F-1

An accurate 3D model of the F-1 engine can now be used for analysis, flow path definition, clearances, and re-creation and manufacturing of the original parts using new materials.

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Reaching the Outer Limits with GibbsCAM and the Mars Rover Wheel

NextIntent saves days of production time and lighter-weight machined parts through the precise machining analysis with GibbsCAM CAD/CAM software

The Breakdown:

CHALLENGE

Creating One-of-a-Kind Parts for the Mars Exploration Rover

Parts and assemblies for the Rover, some machined from solid titanium, contain complex angles and undercut walls, some with thicknesses as small as 1mm (0.040″).

SOLUTION

Next Intent Uses GibbsCAM to Meet Tight Requirements

The successful Mars Rover mission underlines Next Intent’s use of GibbsCAM software to keep material as thin as possible without affecting the structural integrity of parts.

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