Additive manufacturing for ESA Space mechanisms: fine mechanics/product (re)design/manufacturing

The CRRM is a topologically optimized mechanism, fully designed and produced by CSEM with Additive Manufacturing (AM) technology for the Europe Space Agency (ESA). CRRM stands for Compliant Rotation Reducer Mechanism. The CRRM allows for rotary motion reduction with a factor of 10, a useful function for scanning, pointing, calibration or flip mirror mechanisms in space or other types of harsh environment. The manufacturing of the model on the video was performed by CSEM who developed solid competences to additively manufacture small size, high precision parts, including parts with flexible structures. CSEM also collaborates for several years with the local AM industry (3D Precision in this case) to develop the key competences to manufacture flexible parts. In COMAM, the final part will be manufactured by 3D Precision to highlight this local know-how. The performance testing of the CRRM will be executed by Almatech, a key partner in the project. Compliant mechanisms based on Additive Manufacturing open several doors: - new flexures arrangements and shapes are possible, offering more freedom to achieve complex functions (like the CRRM) - thanks to the design freedom, monolithic mechanisms are possible (reducing the number of parts means less issues during assembly, or even no assembly at all!) - thanks to the use of topology optimization, the design can be highly optimized with respect to a variety of parameters (mass, volume, stiffness, eigenmodes, etc…) This development involves multiple cutting-edge engineering know-how which was developed at CSEM during the last 5 years and which is currently unique in the world. Such a high level of complexity was never reached before. Also to be highlighted, CSEM patented a new type of flexible elements (Interlocked Lattice Flexures) which open new perspectives in the field of compliant mechanisms and opportunities for technology transfers to the local industry.