3D Printing Complex Unitized Instrument Optical Benches and Metering Structures

Additive machining technologies have advanced to a point where we they can be utilized effectively for lowering mission costs. However, special design engineering approaches must be understood and demonstrated before additive machining can be used by flight project teams to reduce cost/risk at significant scales. We propose to manufacture an entire complex instrument structure using additive machining to drastically reduce parts count and integration time, and demonstrate the non-standard design approaches required.

Instrument managers are notoriously conservative; Low TRL fabrication technologies are avoided due to cost unpredictability. Use of DMLS to fabricate entire unitary structures in a single build is low TRL but has the potential to drastically reduce mechanical segment costs through the reduction of component costs, and the reduction of integration and alignment time.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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