Fabrisonic 3D printed satellite heat exchangers for NASA’s Jet Propulsion Laboratory

China3D printingNet February 4th, solid metal3D printingExpert Fabrisonic uses its compact SonicLayer 1200 3D printingThe aircraft created a more valuable satellite heat exchanger for NASA’s Jet Propulsion Laboratory (JPL).
Fabrisonic did not use its standard SonicLayer 7200 to produce the temperature regulator and its complicated internal geometry, but chose to deploy its smaller and more efficient machines. Not only did the final assembly prove to be more cost-effective, but its seals also passed JPL’s rigorous testing, including a simulated Atlas V rocket launch.


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The picture shows Fabrisonic at NASA JPL Lab3D printingHeat exchanger.
Use its SonicLayer 1200 3D printingFabrisonic is able to manufacture heat exchangers more cost-effectively than before (as shown in the picture). Picture from Fabrisonic.

Fabrisonic’s ongoing cooperation with NASA

Fabrisonic was founded in 2011 and is a metal3D printingA service provider that uses its proprietary Ultrasonic Additive Manufacturing (UAM) process to fulfill orders. Hybrid manufacturing technology essentially involves ultrasonic welding of metal strips into layers. Once the object is formed, the use of CNC machining will give it more complex features.

Since this technology operates at low temperatures, it can sometimes be used3D printingIntegrating electronic equipment, the company recently tried to make larger hybrid structures. However, more commonly, the process is deployed in aerospace applications, and Fabrisonic has worked with NASA many times.
For example, in cooperation with Luna Innovations, the company managed to integrate3D printingThe sensor is printed directly on NASA fuel pipes, and in another SBIR project, the company is currently developing UAM corrosion-resistant coatings. Now, as part of its recent collaboration with NASA, Fabrisonic has used its UAM process to create another end-use aerospace component.



Image of Atlas V being launched into space.
Fabrisonic3D printingThe components passed NASA’s JPL test, including the simulation of the Atlas V rocket launch (pictured). The picture comes from NASA.

Create a thermostat

In the latest NASA project, Fabrisonic was commissioned by the Utah State University (USU) School of Engineering to develop two unique components for the thermal satellite system. Although Fabrisonic’s SonicLayer 7200 has been used before 3D printingThe machine achieves fully sealed components, but this time, the company’s engineers chose to use a 1200 machine, instead using a more cost-effective build volume of 10 x 10 x 10 inches.

In the production process, the team used a combination of addition and subtraction methods, using CNC machining to create complex fluid channels for the parts, and filling them with support materials. Once placed in place, these supports can effectively prevent excess metal from being squeezed out into the cavity of the device during printing.
In the post-processing, the support material is washed away, and then the parts are processed into the final shape, so that the exchanger has a smooth and accurate fluid passage. In order to test the leak-tightness and leak-proofness of the equipment (which is essential for the end use), they were then subjected to rigorous JPL testing.

In the end, these parts conquered a series of tests, including being submerged under water, withstanding a pressure of 50 psi and simulating the vibration experienced on the Atlas V. After passing the preliminary assessment, the equipment has now been shipped to USU for final testing. A helium leak detector will be used to simulate the vacuum of space.


3D printingThe rise of heat exchangers

Over the years,3D printingIt has been used in the production of many different heat exchangers, with applications ranging from automobiles to the generation of clean energy.
In October 2017, the French chemical company Air Liquide’s3D printingThe heat exchanger received an award from the European Federation of Chemical Engineering (EFCE). According to reports, by steam reforming natural gas, the additive-made reactor can improve the efficiency of its hydrogen production process.

Similarly, GE Research, the R&D arm of the American conglomerate GE, has used3D printingTo produce ultra-low emission heat exchangers for power generation applications. This advanced additive equipment is part of a two-year project aimed at making power plants cleaner and more efficient.

And Farsoon included3D printingIndustry companies have also tried to optimize thermal regulation equipment, and Chinese companies have3DThe proof of concept for copper is printed. By manufacturing the complex spiral equipment as a whole, Farsoon was able to reduce the total cost by 35%.

(Editor in charge: admin)