Camera Head Unit Brackets (CHU)
Satellite launch trackers consist of a combination of two optical cameras. The camera unit is protected by a CHU bracket, which is usually milled from aluminium blocks. Additive manufacturing helps to improve the design freedom and properties of the component. It cuts down on weight, volume and costs compared to conventional production. The printed component is also more rigid. By changing the material, it was possible to optimise the mechanical properties of the material on site, eliminating the need for electrochemical polishing and heat treatment. The Institute of Space Systems at the University of Stuttgart developed the CHU as part of the Flying Laptop satellite, which was developed and launched into space in 2014. It is used to accurately calculate the position and orientation of satellites in space.
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Facts & figures about the example part
Material: AlSi10Mg (conventionally Al 7075)
Weight: 150 g (conventionally 216 g)
Dimensions: 112 mm x 160 mm x 128 mm (AM design)
Volume: 57 cm³ (conventionally 77 cm³)
Build time: three components/substrate plate: 18 h (TruPrint 3000), 7.6 h (TruPrint 5000)
Stress: 125 MPa (conventionally 241 MPa)
Number of layers: 2155, each 60 µm (AM design)
Build rate: 9626 cm³/hr
Created by: German Aerospace Center (DLR) and TRUMPF