Manufacturing high-end components for space missions is a major challenge. Recently in our tool room, we had the privilege of participating in a project that goes high – literally into space. Therefore, here we would like to briefly outline the production of an aluminium chassis for satellites, where it serves as a structural element.
Starting with a duralumin block
It all started for us with 20 kg blocks of duralumin. Duralumin, known for its lightness and high strength, is an ideal material for aerospace applications. It is its light weight that helps reduce the cost of launching satellites. Aluminum alloys offer a high strength-to-weight ratio, allowing the manufactured components to withstand vibration and shock, both during launch and in space. The high thermal conductivity of aluminium alloys is also crucial for temperature control in satellites that are exposed to extreme temperature changes.
Milling on 3-axis CNC milling machine
The initial rough block of duralumin undergoes an intensive 3-axis milling process. This process requires precision, patience and appropriate technological equipment. On our 3-axis CNC milling machine we are able to machine materials with high precision, which is crucial for the production of not only aerospace components. Within a few days, the duralumin block is transformed into a sleek and lightweight chassis, with a final weight of just 500 g and a length of 300 mm.
Finishing operations
Once the milling is complete, it is essential to ensure that the chassis surface meets all technical and aesthetic requirements. This includes removing any burrs, smoothing the surface and applying special surface treatments. Standard surface treatments can include, for example, anodization, which serves to increase resistance to both corrosion and mechanical wear.
Quality control and testing
Every piece we produce then undergoes a thorough quality control to ensure that all technical specifications and relevant standards are met. Finished chassis are tested by our partners in an environment simulating conditions during flight and in space. Such tests include thermal cycling, vacuum tests or exposure of technical assemblies to vibration.
Ready for a space mission
The final product, our tricked-out aluminium chassis, is ready to go into space. The rocket is already waiting for its cargo. We’re proud of every piece of work that makes it into space, and we look forward to the next challenge.
Electroforming s.r.o.
– We meet individual requirements from development to production.
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