Groundbreaking 3D-Printed frictionless gear for space applications

Groundbreaking 3D-Printed frictionless gear for space applications
by Staff Writers
Paris (ESA) Jul 25, 2023

Space equipment is no stranger to being described as "alien artwork", but the latest development from the Swiss team at CSEM, in collaboration with 3D Precision SA and Almatech SA, can rightly earn that moniker. The cutting-edge design they've produced is a unique 3D-printed gear mechanism, one that stands to revolutionize the functionality of critical space instruments. With a construction that mimics the structure of complex bend-based systems, this mechanism has been designed to control the precise rotation of key elements in space operations, ranging from satellite thrusters to telescope lenses or mirrors.

A core challenge of creating moving parts for space operations is the presence of friction, a phenomenon that induces wear and tear on the components. To minimize this, most gears require some form of lubrication, but this introduces another risk - potential contamination of delicate systems. Both the wear and tear and contamination issues are factors that have long been the bane of many space systems, thus prompting the need for more sophisticated solutions.

Enter the Compliant Rotation Reduction Mechanism (CRRM), a design concept that takes a different approach to gear mechanics. As a 'compliant mechanism', the CRRM harnesses the concept of 'elastic deformation' to transmit force. This concept is seen in daily life, such as in bag fasteners or bows and arrows, where force is transmitted through bending.

The CRRM's design incorporates 24 bendable blades that function seamlessly as a unit, with 16 of these blades interlocking. The practical application of this configuration is that it significantly reduces the turning force imposed upon it by a factor of ten, thus allowing incredibly precise control of rotary motion. This precision, in turn, offers a valuable asset for handling sensitive space instruments such as thrusters, sensors, and lenses.

In terms of manufacturing, this mechanism was 3D printed as a whole unit in high-performance stainless steel, a feat undertaken by Swiss company 3D Precision SA. This approach has given birth to a robust and durable mechanism that's poised to withstand the harsh conditions of space.

The performance testing of this CRRM was carried out by another Swiss company, Almatech SA, as part of an ESA Technology Development Element activity. The results of the tests further substantiated the potential of this innovative mechanism to significantly improve the operation and longevity of space systems.

In conclusion, this recent development signals a pivotal moment in the field of space technology. It stands as an example of how progressive designs, coupled with the versatility of 3D printing, can potentially resolve longstanding challenges in the realm of space operations. The successful implementation of the Compliant Rotation Reduction Mechanism could mark the dawn of a new era of space equipment, one characterized by greater durability and enhanced precision.

Research Program: Compliant Rotation Reduction Mechanism