The applications benefit from Siemens' software solution for industrial additive manufacturing. The solution combines generative engineering, topology optimization, predictive analytics, process simulation, build preparation and production management.

Design4AM project
The Design4AM project is based on the collaboration between Siemens and Sonaca, the aerospace design specialist, with financial support from ESA and the Belgian Federal Science Policy Office (Belspo). Design4AM creates a validated process for using Siemens' comprehensive additive manufacturing software to design highly optimized, lightweight structural components for space applications. These include fittings (structurally bonded to CFRP plates), brackets and bipods for improved performance and cost.

"With our extensive aerospace knowledge and Siemens' software technologies - such as generative design, automated topology optimization and simulation of additive manufacturing processes - engineers will be able to explore hundreds of design options in a fraction of the usual time," said Pedro Romero Fernandez, Sonaca General Manager Space BU. "They can then test them virtually against a variety of physical conditions. This helps them find the best design solution for their performance requirements, and the 3D print is correct the first time."

Additive manufacturing is an important tool for the aerospace industry. It fulfills structural and multidisciplinary requirements for space applications at a significantly lower weight than structures produced using traditional manufacturing methods. Weight is a particularly critical aspect for aerospace applications. According to industry reports, one pound of payload is equivalent to $10,000 in launch costs. Additive manufacturing techniques can help lighten almost any type of complex structure in launch vehicles, engines, satellites and various spacecraft components.

Design4AM leverages the Siemens Digital Innovation Platform and Sonaca's experience in space applications, manufacturing properties, materials handling, testing and numerical methods to validate the process chain. Siemens' NX and Simcenter software solutions enable engineers to explore a variety of design concepts in an automated closed-loop process that considers engineering performance, manufacturing process and operational cost requirements. These solutions can take into account manufacturing constraints such as thermo-mechanical part deformation, part orientation in the build chamber or the design of support structures. The integrated software environment shortens the component design and optimization process and enables the production of high-performance structures.

Production of highly resilient structures
"Additive manufacturing helps ESA to optimize processes and thus achieve optimal performance at reduced costs. In comparison, traditional manufacturing methods require several processing steps and tools to achieve the desired result," says Didier Granville, RTD project manager at Siemens in Liège. "Together with Sonaca, we are helping ESA to take advantage of additive manufacturing to produce highly resilient structures that can withstand the extreme forces involved in launching space satellites." as