Design and testing of selective laser melted structural component in AlSi9Cu3 alloy for a space dust analyser

Abstract Space is one of the most avant-garde sectors for additive manufacturing as the inherent characteristics of this technology allow the creation of complex and lightweight 3D structures. Using this brand-new design tool, it was possible to design the pumping system holder of the MicroMED instrument, a particle analyser developed for ExoMars 2022 mission. The geometry of the holder was optimized using a finite element approach. The effectiveness of the proposed solution was evaluated by comparing the performance of two different designs using the AlSi9Cu3 alloy. One solution was based on micro-milling and the other on Selective Laser Melting. In order to validate the designed SLMed holder, a mockup was produced and successfully tested in the mission's mechanical environment.