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3D printing consolidates satellite antenna from 100 parts to 1 | Protolabs Network

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One of the strengths of metal printing is the ability to consolidate parts. Because of the design freedom offered by 3D printing, factors such as tool paths, undercuts and assembly access can all be ignored, allowing full assemblies to be produced as in a single 3D printed part. By reducing part count, both maintenance and service requirements can also be reduced. Optisys LLC are a provider of micro-antenna products for high performance aerospace and defense applications. A recent project involved a complete redesign of a high-bandwidth, directional tracking antenna array, known as a Ka-band 4 × 4 Monopulse Array. Optisys performed every aspect of the design work in-house and printed the component in a single piece on an SLM machine by Concept Laser. Manufacturing antenna systems made via conventional methods, such as brazing and plunge Electrical Discharge Machining (EDM) require a complex, multistage process that can take an average of eight months of development time ...

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