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The torus holds the fuel and provides the structure for the satellite. Since complexity is free when 3D printing, fixtures and cable routing and alignment of the space bus elements are embedded in the design. A sacrificial mold is printed (see below), and then dipped in ceramic to form an investment cast for the titanium structure you see here.

Peter Diamandis and Chris Lewicki (JPL Flight Director for Mars rovers Spirit and Opportunity) brought this early build of their Arkyd satellite, and I now have permission to share.

The telescope is in the center of the hollow toroid fuel tank, with the camera / thermal sensor array facing us.

7 responses to “Unveiling the Revolutionary 3D-Printed Satellite from Planetary Resources”

  1. The other side, with telescope / laser coms face:IMG_5431 and I caught a glimpse of the mold at TED last week in a talk by the 3D-printing tool maker: TED2014 AR 3d printing Talk

  2. Interesting! I am wondering though why to take the detour with the mold and not sinter directly in titanium?

  3. I am guessing this investment casting approach (using a 3D Systems printer) might be cheaper and faster, and the 25cm build envelope of direct titanium laser sintering would have to be overcome. In this specific context, pressure vessels are not easy, and manufacturing confidence is critical for range safety clearances. The range will probably need a lot of test data and handholding before approving a 3D-printed pressure vessel on a rocket.

    Now, here’s an interesting example of convergent evolution: Moon Express showed their new lunar lander design on a panel I moderated yesterday, and it has also moved to a torus (with composites).

    DSC00345

    And zooming in on the MX-1
    Moon express torus MX-1

    The secondary payload interface constrains the height, and the design space started with traditional fuel tanks in a ring around a central engine (e.g., Armadillo’s Texel), and then someone thought of the advantages of a torus, and in the modern era, the benefits of 3D printing make it more compelling.

    Here is the prior Moon Ex design that they inherited from NASA
    Moon Express Lander

  4. 3d hybrid investment casting has much more artistic value too, cire perdue meets topology optimization
    sffsymposium.engr.utexas.edu/Manuscripts/2012/2012-11-Mei…

  5. As the Soviets used to say, "we invented it first."

    Here’s the "Block-D" stage developed for the N-1 moon rocket (still in use today as the top stage of the Proton booster).

    http://www.flickr.com/photos/31160766@N02/17131391380/

  6. Nice find. From your book, I presume. =))

    Meanwhile, mining is now barely legal.

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