the esa advanced manufacturing initiative as innovation driver …€¦ · the esa advanced...
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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, [email protected]
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.
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Advanced Manufacturing
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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)
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ESA Advanced Manufacturing Cross Cutting Initiative
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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
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Additive Manufacturing
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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
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Demonstrator: Reaction wheel bracket for Exomars TGO
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Reaction wheel bracket trade-off
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• 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
[email protected] (Head of the Structures, Mechanisms and Materials Division)
[email protected] (Head of Materials and Processes Section)
• Design 2 Produce cross-cutting initiative
[email protected] (Systems and Concurrent Engineering Section)
ESA UNCLASSIFIED - For Official Use Thomas Rohr | ESTEC | 14/04/2018 | Slide 29
Thank you for your attention!