Maxar Technologies successfully launched five spacecraft with 260 titanium 3D printed parts

China3D printingNet, June 2nd, Auckland-based 3D titanium printing company Zenith Tecnica is celebrating a five-year partnership with satellite manufacturer Maxar Technologies for the company’s spacecraft.3D printing260 titanium components were used.
Since 2016, Maxar Technologies has built and launched five ships equipped with Zenith Tecnica 3D printingParts of the spacecraft, and another 270 additively manufactured parts are currently being produced on eight other satellites.

“Maxar is committed to additive manufacturing and is an excellent customer,” said Peter Sefont, Technical Director of Zenith Tecnica. “The team is pragmatic and works with suppliers to successfully take advantage of all the advantages provided by additive manufacturing. We are very proud to be involved in the manufacture of their spacecraft.”



The SXM-8 manufactured by Maxar is in full flight configuration at Maxar’s manufacturing plant in Palo Alto, California. Photo from Maxar Technologies.

Zenith Tecnica’s 3D printingTitanium components

Since its establishment in 2014, Zenith Tecnica has become one of the world’s most productive electron beam melting (EBM) metal 3D printing service organizations.
The company uses EBM printers from Arcam AB, a subsidiary of GE Additive, added a third and fourth machine in 2015, and added two Q10 plus systems in 2019.
Arcam’s patented EBM process can increase the build platform and chamber temperature without the need for post-printing heat treatment stress relief. One of the unique advantages of EBM technology is that the process is carried out in a vacuum, eliminating the possibility of gas contamination.

Zenith Tecnica used its Arcam machine to produce 3D printed metal aircraft parts during its ongoing cooperation with Air New Zealand. The company 3D printed wine aerators, cocktail trays and the metal frame of the in-flight entertainment screen used in the interior of the Air New Zealand aircraft.
In 2016, Zenith Tecnica obtained the qualification to produce unmanned space components, and two years later, its first satellite component was put into orbit.

3D printingSatellite components. Photo courtesy of Zenith Tecnica.

Zenith and Maxar’s ongoing partnership

Utilizing Zenith Tecnica’s Titanium3D printingFunctionality, the company’s customers can optimize the hardware and thermal characteristics of parts designed for specific satellite functions and payloads.
Zenith Tecnica’s 3D printing technology enables designs that were previously impossible with traditional manufacturing methods, and can provide parts with lighter weight, fewer hardware, and longer on-orbit life.

Maxar Technologies is an early adopter of additive manufacturing and established the Additive Center of Excellence in 2012. After verification and appraisal process, Zenith Tecnica’s EBM titanium material and process obtained flight qualification. In 2016, the first batch of EBM titanium parts were sent to orbit.
Prior to heat treatment and processing of key assembly features, the titanium satellite parts were 3D printed using Zenith Tecnica’s Arcam EBM machine. Then perform a 3D scan check to ensure that all parts meet specifications.
According to China3D printingNet understands that since the introduction of Zenith Tecnica’s additive manufacturing capabilities for the production of spacecraft components, Maxar Technologies has seen a number of benefits, including increased planning flexibility, reduced manufacturing costs, and improved satellite performance.

Maxar Technologies Additive Manufacturing Technology Manager Gina Ghiglieri said: “Zenith Tecnica’s team is an extension of Maxar’s team, and they always double their efforts to ensure that the quality of the delivered parts meets high standards. “Since Maxar’s first metal additive manufacturing project , Zenith Tecnica has been working with us and has played a key role in helping to define and validate these production processes. “
So far, the two companies have jointly launched five spacecraft with 260 3D printed titanium parts during the cooperation period, and the two companies have another 270 additional 3D printed parts in the production and assembly of eight other satellites.



3D printed satellite components. Photo courtesy of Zenith Tecnica.

satellite3D printing

3D printing is increasingly used to produce optimized satellite components, such as radio frequency (rf) circuits, waveguide signal interconnects, and ceramic antennas. Last year, Canadian Manufacturing Services Agency Burloak Technologies and communications company MacDonald, Dettwiler and Associates (MDA) signed a new five-year agreement to continue to optimize the design and production of 3D printed satellite components.

Since the beginning of 2021, metal 3D printing expert Fabrisonic has deployed its proprietary Ultrasonic Additive Manufacturing (UAM) technology to supply NASA’s Jet Propulsion Laboratory, the Skolkovo Institute of Science and Technology (Skoltech) and materials supply RUSAL creates higher-value satellite heat exchangers using new aluminum materials to provide 3D printed shells for the Yarilo satellites.

Recently, aerospace manufacturer Airbus announced that it has 3D printed 500 RF components for Eutelsat’s Eurostar Neo series of relay satellites. Marking the entry into mass production, Airbus can significantly reduce the delivery time and cost of components, which will be installed on two Eutelsat Hotbird spacecraft and launched into low earth orbit (LEO).

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