We designed and manufactured a 500 mm tubular satellite strut with low CTE (Coefficient of Thermal Expansion) in accordance with space requirements that demand a maximum void content of 1.5%. Through our iterative digital manufacturing process, we successfully reduced the void content from approximately 4.5% to an impressive ~1%.
Our approach leveraged multi-scale micro-CT scanning, a powerful tool for identifying tape gaps and overlap defects that are common in automated fibre placement manufacturing. This advanced scanning technique allowed us to pinpoint gaps between tapes in specific layers and digitally isolate them. These voids in the final product were then cross-referenced with the process data to determine the layers on which they occurred, and the width of each tape involved.
Utilising this precise information, we iterated and optimised the design and manufacturing process, ensuring the production of an improved satellite strut.
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