Client: Leading Small Sat Manufacturer
Industry: Space & Satellite
Manufacturing Process: 5-Axis CNC Machining & Additive Manufacturing
Material: Titanium Alloy (Ti-6Al-4V)
Challenge: Lightweight, high-strength components for extreme space environments
Background
A small satellite (SmallSat) manufacturer developing a Low Earth Orbit (LEO) satellite constellation approached 8X Parts Inc. to produce high-strength, lightweight titanium brackets for their structural framework. These brackets needed to withstand the intense vibrations of launch, thermal cycling in orbit, and long-term exposure to space radiation—all while keeping weight to a minimum.
Challenges
The project presented several key technical and production challenges:
Extreme Durability: The brackets had to resist thermal expansion and stress fractures over multiple years in space.
Weight Optimization: Every gram saved would contribute to launch cost reduction and improved payload efficiency.
Precision Machining: Tight tolerances were required for seamless integration with other satellite components.
Rapid Prototyping & Production: The client had a strict launch schedule, requiring a fast turnaround for both prototypes and final production parts.
Solution
To meet these demands, 8X Parts Inc. deployed a hybrid manufacturing approach, leveraging both 5-axis CNC machining and additive manufacturing to optimize the design and performance of the titanium brackets.
Advanced Manufacturing Process:
✔ Material Selection: Ti-6Al-4V was chosen for its superior strength-to-weight ratio, corrosion resistance, and proven performance in aerospace applications.
✔ Precision CNC Machining: Using 5-axis milling, we achieved ±0.0002 inches tolerances, ensuring flawless alignment with the satellite’s structure.
✔ Additive Manufacturing Enhancements:3D-printed lattice structures were integrated to reduce weight by 20% while maintaining mechanical integrity.
✔ Post-Processing & Testing: The components underwent heat treatment, surface finishing, and vibration testing to validate launch readiness.
Results & Impact
🚀 20% Weight Reduction: The optimized bracket design improved payload efficiency without compromising strength.
🔧 Increased Structural Integrity: The parts passed rigorous vibration and thermal cycling tests, ensuring long-term durability in orbit.
⏳ 50% Faster Production Time: Prototypes were delivered in under 14 days, allowing the client to meet their aggressive launch schedule.
💰 Cost Savings: The use of hybrid manufacturing reduced material waste and machining time, lowering production costs by 15%.
Summary
By leveraging advanced CNC machining and additive manufacturing, 8X Parts Inc. successfully delivered high-performance titanium brackets that enabled the client’s satellite to meet its structural and performance goals.
📡 Need precision-engineered components for your space mission? Contact 8X Parts Inc. today to discuss your satellite manufacturing needs.