Star Tracker Bracket - Challenge

Turkish Aerospace Industries (TAI) has become Turkey's center of technology in design, development, modernization, manufacturing, integration, and life cycle support of integrated aerospace systems, from fixed and rotary wing air platforms to UAVs and satellites. An important part of such a satellite is the so-called star tracker bracket which holds an optical device for controlling and steering the exact position of a satellite in orbit. Currently, such a bracket consists of more than 400 individual parts and has its own cooling circuit to prevent it from deformation by the heat of the sunbeams which would make the exact positioning of the satellite impossible. Due to these requirements, the component is heavy and complex. A weight reduction of 30 % and a functional integration of the cooling circuit is the declared aim of TAI. In this ongoing project, an innovative design and manufacturing solution for a new and better star tracker bracket is sought to guarantee a safe launch and reliable positioning of the satellite in orbit for many years.

Star Tracker Bracket - Challenge
Star Tracker Bracket - FIT Solution

Star Tracker Bracket - FIT Solution

Rapid Prototyping as part of an ADM-Q project (production of end-use parts)

Feasibility check
Result: Additive manufacturing of the star tracker bracket considering the very hard requirements of a rocket launch (e.g. 20 G acceleration force in all directions) and according to the European standards and guidelines for the aerospace industry is possible, but a redesign for reducing the weight and for the optimization of the cooling system is necessary.

Feasibility study
- Currently recommended material: Titan Gr. 5
- Currently recommended technology: Electron Beam Melting (EBM)

Rapid prototyping
Additive manufacturing of the bracket with our quality-approved AM process for Electron Beam Melting (EBM)

Finishing
- Support removal
- Blasting
- CNC milling

Quality assurance
- CT scan after blasting
- GOM scan after CNC milling
- Measurement and control of tensile tests and density cubes

Next step:
ADM-E project

Additively optimized redesign of the component


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