Montreal Space Symposium 2019

Mohammad Rafiee, PHD, Clément Broggi, MSc
Design and 3D printing of a high performance thermoplastic lunar rover
3D printing is on verge to become a powerful way of manufacturing. Using a printer, one is able to produce complex parts, optimized for a specific application and thus with a lower mass. The Fused Deposition Modelling process is cheap and allow to produce parts it would be impossible to manufacture using traditional means. However, thermoplastics -commonly used material- do not possess, most of the time, the mechanicals properties required to 3D print structural parts and to be of interest for space applications. Some new high-performance thermoplastic composites could be a game changer.
This talk focus on the design and manufacturing of a lunar rover, printed in a high-performance thermoplastic, in partnership with the Canadian Space Agency. Lunar rovers and space parts in general, are made from aluminium because of its mechanical, thermal, and radiation properties. Composites could be a material of choice to lower the mass of the rover, provide better thermal insulation, and tailor properties to the requirements of the mission.   3D printing could allow designing a structure capable of surviving to the moon environment by reducing the amount of inserts and bolts, therefore reducing mass, but also reducing potential path of heat loss.
After a quick presentation of 3D printing, the design strategy will be explained. Finally, the up to date rover concept will be presented.