The objective of the activity is to develop software methods to demonstrate the reduction in environmental impact of applying smart manufacturing techniques, in comparison to conventional manufacturing approaches. This will be demonstrated on a primary structural part (e.g. main load bearing panel or central tube) for a typical telecommunication satellite platform.Targeted Improvements:- 30% material usage reduction in comparison to conventional manufacture. - 30% energy consumption reduction in comparison to conventional manufacture.Description: Currently, hardware for satellite structures is manufactured primarily using conventional machining techniques such as milling. Material and energy usage is not routinely monitored during such machining operations. This leads to an unquantified environmental impact that accumulates when producing a series of parts as required for satellite constellations. Smart manufacturing is the idea of organising physical and digital processes within factories and supply chains to optimise supply and demand requirements, as used in other industries. It is possible to optimise manufacturing processes and significantly reduce product waste. For example, monitoring energy usage data in real time when machining to optimise machining parameters and reduce waste. Further waste reduction is possible by replacing conventional machining with advanced manufacture (e.g. additive manufacturing). This activity aims to demonstrate smart manufacture for series production of telecommunication satellites. A trade-off analysis will be conducted, selecting a typical primary structure part where the benefits of introducing smart manufacturing techniques will be demonstrated, compared to the conventional approach. A smart manufacturing route will be defined for the design of the part. Advanced manufacturing routes such as additive manufacture will be considered to achieve additional energy and material savings. Data will be gathered on the various manufacturing processes, to create a data lake and automate the generation and update of these datasets. By using and adapting existing data science frameworks and data analytics, data patterns will be predicted for each manufacturing process. Existing sensor technologies will be exploited to take measurements, including, but not limited to, temperature maps and time-series. If justified, existing sensors could be modified or bespoke sensors could be developed. A life cycle assessment will compare the conventional and alternative manufacturing routes to assess the environmental impact reduction (material and energy). The software developed in this activity shall be designed, developed, manufactured, and tested. The deliverable shall be the source code; both open source and commercial software solutions are permissible.Procurement Policy: C(1) = Activity restricted to non-prime contractors (incl. SMEs). For additional information please go to:…

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