ADDITIVE MANUFACTURING FOR D4D: THERMOPLASTIC DEMISABLE JOINTS FOR HIGH ALTITUDE BREAK-UP

Abstract

To ensure that near-Earth space remains commercially and scientifically viable in the future, it is of great importance to reduce the amount of space debris in orbit and minimize the generation of new debris. At DLR Institute of Structures and Design in Stuttgart, we explore how additive manufacturing can be used for "Design for Demise (D4D)", primarily through its freedom of form, but also by influencing material behavior for a more efficient demise process. The overall aim was to use additive manufacturing to create demisable designs for joining primary structures, where it breaks apart during re-entry at higher altitudes than it would normally do. Demisable joint concepts made of 3D printed CF-PEEK were developed and later upgraded with passive ejection mechanisms using preloaded springs and shape memory materials. Thermomechanical analyses and successful preliminary plasma wind tunnel tests are presented.