ESA UNCLASSIFIED - For Official Use

The ESA advanced manufacturing initiative as innovation driver for European space industry

Thomas RohrHead of Materials and Processes SectionMechanical DepartmentESA, ESTECThomas.Rohr@esa.int

Innov'action Aerospace 4.0Liège, Belgium, 17th April 2018

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 2

Agenda

• Introduction to ESA

• Advanced manufacturing cross-cutting initiative

• Design 2 Produce cross-cutting initiative

• Case studies for advanced manufacturing

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 3

ESA facts and figures

Over 50 years of experience

22 Member States

Eight sites/facilities in Europe, about 2300 staff

5.75 billion Euro budget (2017)

Over 80 satellites designed, tested and operated in flight

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 4

Member States

ESA has 22 Member States: 20 states of the EU (AT, BE, CZ, DE, DK, EE, ES, FI, FR, IT, GR, HU, IE, LU, NL, PT, PL, RO, SE, UK) plus Norway and Switzerland.

Seven other EU states have Cooperation Agreements with ESA: Bulgaria, Cyprus, Latvia, Lithuania, Malta and Slovakia. Discussions are ongoing with Croatia.

Slovenia is an Associate Member.Canada takes part in some programmes under a long-standing Cooperation Agreement.

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 5

Activities

ESA is one of the few space agencies in the world to combine responsibility in nearly all areas of space activity.

* Space science is a Mandatory programme, all Member States contribute to it according to GNP. All other programmes are Optional, funded ‘a la carte’ by Participating States.

space science

telecommunications

human spaceflight exploration

earth observation launchers navigation

operations technology

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 6

Washington

Houston

Kourou

Maspalomas

Santa Maria

New Norcia

Moscow

ESRIN (Rome)

Oberpfaffenhofen

ESOC (Darmstadt)

EAC (Cologne)

Salmijaervi (Kiruna)

ESTEC (Noordwijk)ECSAT (Harwell)

Toulouse

Brussels

Cebreros

ESA HQ (Paris)

Redu

MalargüeESA sites

OfficesESA Ground Station

ESA Ground Station + Offices

ESA sites + ESA Ground Station

ESA’s locations

ESAC (Madrid)

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 7

Programmes implementedfor other institutional partners

Income from Eumetsat:9.3%, 182.7 M€

Other income:4.6%, 90.7 M€

Income from EU:86.1%, 1697.9 M€

Total:1.97 B€

ESA budget for 2017: 5.75 B€

ESA Activities and Programmes

B€: Billion Euro M€: Million Euro

CA: 0.3%, 13.1 M€

UK: 7.9%, 300.0 M€

SE: 1.9%, 72.3 M€

ES: 4.0%, 151.2 M€ SL: 0.1%, 3.4 M€

NO: 1.7%, 63.5 M€

NL: 1.9%, 72.0 M€

LU: 0.6%, 22.3 M€

IT: 14.6%, 550.0 M€

IE: 0.5%, 17.8 M€

GR: 0.4%, 14.6 M€

AT: 1.2%, 47.1 M€

BE: 5.5%, 206.0 M€

CZ: 0.9%, 32.7 M€

DK: 0.8%, 30.5 M€

FI: 0.5%, 19.4 M€

DE: 22.7%, 858.4 M€

RO: 0.8%, 30.0 M€

PL: 0.9%, 34.6 M€

Other: 5.6%, 209.8 M€

Total:3.78 B€

EE: 0.1%, 2.5 M€

HU: 0.2%, 6.2 M€

PT: 0.5%, 17.0 M€

CH: 3.8%, 145.1 M€

FR: 22.7%, 855.9 M€

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 8

ESA’s industrial policy

Ensures that Member States get a fair return on their investment;

Improves competitiveness of European industry;

Maintains and develops space technology;

Exploits the advantages of free competitive bidding, except where incompatible with objectives of the industrial policy.

About 85% of ESA’s budget is spent on contracts with European industry.

ESA’s industrial policy:

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 9

Space 4.0: a new era of space

Space 4.0 represents the evolution of the space sector into a new era:

From being the preserve of the governments of a few spacefaring nations, to an increased number of diverse space actors around the world;

With the emergence of private companies, participation with academia, industry and citizens, digitalisation and global interaction;

Analogous to, and is intertwined with, Industry 4.0, which is considered as the unfolding fourth industrial revolution of manufacturing and services.

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 10

Advanced Manufacturing

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 11

Advanced manufacturing - objectives

To create new high performance Space products by actively reducing the limitations imposed by the traditional manufacturing processes/concepts

Profit of the ideal opportunities in Europe to spin-in the digital manufacturing technologies and Industry 4.0 to space

Identify and implement new manufacturing technologies for space applications enabling:

Design freedom

Performance improvement

Costs reduction

Lead time reduction(from concept to manufacturing)

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 12

ESA Advanced Manufacturing Cross Cutting Initiative

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 13

Image source: dragoart.com

Terrestrial AM

Aim A

• Roadmap proposes about 30 types of parts (AIM A)

• Roadmap proposes technology developments (Aims B to F)

• Roadmap endorsed by the IPC

o More than 700 experts /stake holders involved

o 26 countries representedo 390 companies representedo 62 new members joined the

roadmap space community

o Available for everyone in Europeo => Eurospace

European Harmonisation Roadmap on Additive Manufacturing for Space

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 14

GSTP-6 Element 1 Compendium of Potential Activities Advanced Manufacturing

• Initial set of Advanced Manufacturing technologies identified following an extensive technical and programmatic coordination work with ESA as well industrial end-users

• The resulting THAG Roadmaps for Additive Manufacturing and Composites Materials used to establish the GSTP-6 Element 1 Compendium of Potential Advanced Manufacturing activities

• Revision 2 for of AM GSTP compendium published Nov 2015 covering areas of materials processing, surface engineering, shaping, joining, and assembly. Overall proposed activities for 29.6 M€.

• A new batch of proposals is under development

• More information: www.emits.esa.int → news

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 15

Design 2 Produce

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 16

D2P objective is to improve the space systems end-to-end development process, reducing engineering lead time and budget, in particular by introducing innovative techniques and benefit from spin-in from non-space.

The challenge to design space systems towards production, integration and verification, is feeding relevant lessons learned from the late phases back to the design.

This challenge has been already addressed for mega-constellations

The need is to adapt processes to one-offs, in order to serve the competitiveness of the European Space Industry.

Implementation of GSTP Compendium of Proposed Activities: Submitted to Delegations in June 2017, with activities based on the highlighted lines of actions

Design 2 Produce – objectives and challenges

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 17

Design 2 ProduceI CANT’T FIND

DIMENSIONS IN THE DATA PACKAGE!

THE CAD MODEL CONTAINS THEM.

I WILL EMAIL THEM TO YOU!

WE HAVE TO FOLLOW THE

ASSEMBLY PROCEDURE.

WAIT!I CAN’T ACCESS

THE JOINT!

ALL DATA ARE CONSISTENT AND AVAILABLE IN THE DIGITAL MODEL

ARE WE READY TO SEND OUR DESIGN

DATA TO PRODUCTION?

I HAVE JUST GOT AN UPDATE FROM OUR VIRTUAL A.I.T. TEAM. LET’S UPDATE

DESIGN DATA

I’LL FOCUS ON MORE CRITICAL ASPECT AND THE ROBOT WILL TAKE CARE OF

REPETITIVE TASKS!

THIS INTERFACE WOULD NOT WORK! LET’S SEND INFO BACK TO

DESIGN TEAM BEFORE PRODUCTION STARTS!

OK, I’VE GOT MY VIRTUAL SCREEN READY TO SHARE

THE INFORMATION

DIGITAL MODEL

PRODUCTION

VIRTUAL A.I.T.2020

ARE YOU SURE THAT THE CAD REFLECTS THE “AS-BUILT”?

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 18

Design 2 Produce: lines of actionSchedule and Cost reduction shall be achieved acting throughout the entire system lifecycle. 3 lines of action (*) have been identified:

Digital Engineering:

Creation and adoption of Digital Model and Digital Engineering

for the E2E System Development, throughout the entire supply chain

Embedded Sensors:

Improvement of design and product, based on analysis of data from embedded sensors (on-ground and on-board)

Enhancements in AIT, based on embedded sensors for monitoring and logistics

Latest Generation Techniques for the shop floor:

Application of latest generation techniques (AR/VR, automation, …), and methods supporting preparation and execution of AIT procedures, preventing anomalies and failures and reducing inefficiencies

(*) resulting form a prioritization exercise run though brainstorms/meetings/discussions with space and non-space stakeholders from April 2016 till now

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 19

Additive Manufacturing

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 20

ESA Additive Manufacturing Benchmarking Center –Coventry, UK• AM of space hardware => small, medium and large parts

• Services for :

• ESA Projects/ESA Directorates: access to state-of-the-art 3D Printing capabilities (metallic/non-metallic)

• Industry to mature their AM products and process understanding

• Benchmarking of:

• AM powders

• produced materials

• post processing techniques

• AM machines

• Failure investigation/re-manufacture of parts

• Publication of a European Newsletter with all results generated by the Centre

• Consolidate European leadership on AM

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 21

• ESA Harwell Advanced Manufacturing Test Services

• Complementing the existing ESTEC Materials & Processes network of external facility

• Pre-screening of advanced materials and manufacturing processes towards space flight qualification

• ALM capabilities available

Purpose of the laboratory

Testing of advanced materials and manufacturing processes for low-TRL projects and R&D, focusing on:

• Additive Layer Manufacturing (ALM)

• Advanced Joining Technologies

• Advanced Materials and Processes

Exploit facilities available on Harwell Campus

ESA-RAL Advanced Manufacturing Laboratory –Harwell, UK

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 22

Objectives: Improve the IBDM ring in terms of:

• mass,

• cost and

• environmental impact (LCA).

Demonstrator built through WAAM and subsequent machining

Docking photo: Soyuz spacecraft docked to ISS (Photo: NASA)

Demonstrator model for IBDM ring

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 23

ATHENA Optical Bench with Additive Manufacturing

o Materials trade-off: E/ρ → max, CTE → low

o TRP project: Ti alloy chosen due to manufacturability

o Produced through Laser Powder Build-up Welding (LPBW) at Fraunhofer IWS

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 24

ATHENA optical bench with Additive Manufacturing

o 16 axis twin robot system

o Turn-tilt table

o 1 robot performs welding task

o 1 robot performs milling task

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 25

Demonstrator: Reaction wheel bracket for Exomars TGO

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 26

Reaction wheel bracket trade-off

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 27

• Advanced Manufacturing and Design 2 Produce are cross-cutting initiatives at ESA

• Advanced manufacturing targets four main areas are:

o Design freedom

o Performance improvement

o Costs reduction

o Lead time reduction (from concept to manufacturing)

• Manufacturing of components using the most appropriate material(s) and technology

• In 2017 ESA committed around 17 M€ of activities. In 2018, this will be in excess of 25 M€

Summary

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 28

Doing business with ESA

Industry portal

How to do: https://www.esa.int/About_Us/Business_with_ESA/How_to_do

SME: https://www.esa.int/About_Us/Business_with_ESA/Small_and_Medium_Sized_Enterprises

Shaping the future: https://www.esa.int/Our_Activities/Space_Engineering_Technology/Shaping_the_Future

Invitations to tender: http://emits.sso.esa.int/emits/owa/emits.main

Tendering system: https://esastar-emr.sso.esa.int/

Points of contact

• Advanced manufacturing cross-cutting initiative

Tommaso.Ghidini@esa.int (Head of the Structures, Mechanisms and Materials Division)

Thomas.Rohr@esa.int (Head of Materials and Processes Section)

• Design 2 Produce cross-cutting initiative

Ilaria.Roma@esa.int (Systems and Concurrent Engineering Section)

ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 29

Thank you for your attention!