Space Hardware Advanced Manufacturing Engineering: SHAME to miss out on a potential game changer?

Advanced Manufacturing is widely used with features and applications playing a game changing role in our daily life. The European Space Agency has initiated in April 2016 a multi-disciplinary approach exploring the impact of infusing Advanced Manufacturing into space practices. A Concurrent Design Facility study was performed investigating potential design methodology amendments produced by introducing Advanced Manufacturing techniques into the design space. Innovative materials and processes were added to the conventional design parameters usually populating the systems design trade-spaces. This enabled multifunctional solutions, previously inconceivable, with a redefinition of interfaces and related requirements, shifted from ‘discipline’ boundaries to ‘units’ or ‘assembly’ boundaries. The Concurrent Design Facility Study identified the core domains of expertise required in a ‘Design for Advanced Manufacturing’ frame, governed by a flexible, open-minded systems engineering coordination. Early involvement of material and process engineers in the design proved to be an essential ingredient of the ‘Design for Advanced Manufacturing’ recipe. The design freedom brought by Advanced Manufacturing calls for unconventional design solutions, creativity becomes a need and infusion from non-space is invaluable. Biomimicry and architecture principles enriched the concurrent design environment, which proved to be very well suited with the needs and objectives of the new design methodology. This article reports the Concurrent Design Facility study conduct, as first attempt to understand Advanced Manufacturing impact on design methodology, the study cases selected for analysis, the observations on the methodology and on the interactions among the specialists in the team. The study outcome is reported, including an overview of benefits, disadvantages and points for further investigation in relation to the study cases assessed. In addition, the paper proposes recommendations for injecting Advanced Manufacturing into the project life cycle, from early design up to procurement phases and ultimately to the assembly, integration and verification phases, indicating required modelling tools, technologies and redefined engineering roles and expertise