Development of a Specialized Mounting Component for a Satellite System
The company Dartsat faced a technically demanding challenge: to develop a mounting component for attaching a non-standard radiator to the parabolic antenna of a ground station. No off-the-shelf solution existed for this application, making it necessary to design an entirely new technical solution precisely tailored to the specific requirements.
At Brain4Industry, we were involved in the project from the initial design through to the final manufacturing of the component. The goal was to create a technically optimized part that meets strict requirements for low weight, sufficient strength, and load-bearing capacity, while also ensuring maximum efficiency in material usage and production costs.
Although the assignment appeared straightforward at first glance, it was technologically highly complex. It was essential to minimize the component’s weight without compromising mechanical resistance or functionality. Topology optimization therefore played a key role, enabling detailed load analysis and identification of areas subjected to the highest mechanical stress. Based on simulation results, a design was created in which material is used only where it has real functional significance.
The component itself was manufactured using SLM (Selective Laser Melting) technology from aluminum. Metal 3D printing made it possible to produce a lightweight, strength-optimized part with complex geometry that would be impossible to manufacture efficiently using conventional methods. The result is a structure precisely tailored to its purpose, free of unnecessary material and design compromises.
For the client, this solution delivers several major benefits: significant weight and material savings, reduced production costs, and above all a technically optimized component designed specifically for its application within a satellite system. The project also demonstrates how a combination of simulation tools, topology optimization, and additive manufacturing can be used to effectively address even very specific technical challenges.
Do you have a technically demanding product and are looking for a partner capable of handling development, optimization, and implementation of an innovative solution? At Brain4Industry, we can help you move your project forward—from the initial concept to a complete, fully realized solution.
