Additive manufacturing has introduced a great step in the manufacturing process of consumer goods. Fused Deposition Modeling (FDM) and in particular 3D printers for home desktop applications are employed in the construction of prototypes, models and in general in non-structural objects. The aim of this new work is to characterize this process in order to apply this technology in the construction of aeronautical structural parts when stresses are not excessive. An example is the construction of the PoliDrone UAV, a multicopter patented, designed and realized by researchers at Politecnico di Torino. For this purpose, a statistical characterization of the mechanical properties of ABS (Acrylonitrile Butadiene Styrene) specimens in compression tests is proposed in analogy with the past authors’ work about the tensile characterization of ABS specimens. A desktop 3D printer, including ABS filaments as the material, has been employed. ASTM 625 has been considered as the reference normative. A capability analysis has also been used as a reference method to evaluate the boundaries of acceptance for both mechanical and dimensional performances. The statistical characterization and the capability analysis are here proposed in an extensive form in order to validate a general method that will be used for further tests in a wider context.

Anti-ice systems assure a vital on-board function in most aircraft: ice prevention or de-icing is mandatory for all aerodynamic surfaces to preserve their performance, and for all the movable surfaces to allow the proper control of the plane. In this work, a novel multi-functional panel concept which integrates anti-icing directly inside the primary structure is presented. In fact, constructing the core of the sandwich with trabecular non-stochastic cells allows the presence of a heat exchanger directly inside the structure with a savings in weight and an improvement in thermal efficiency. This solution can be realized easily in a single-piece component using Additive Manufacturing (AM) technology without the need for joints, gluing, or welding. The objective of this study is to preliminarily investigate the mechanical properties of the core constructed with Selective Laser Melting (SLM); through the Design of Experiment (DOE), different design parameters were varied to understand how they affect the compression behaviour.

This work proposes a composite construction material made by a blend of lunar regolith and thermoplastic binders in dry powder form. This solution offers advantages over regolith sintering or melting by requiring lower power consumption and simplifying the manufacturing process. However, its sustainability depends on minimizing the content of the binder material. Drawing from validated concepts used on Earth, such as polymeric concrete and compressed Earth bricks, this paper suggests that binder optimization can be achieved by simplifying and streamlining the manufacturing process, targeting parts with predefined shapes. Standardized elements like bricks or tiles ease production and assembly automation, especially when incorporating interlocking features, simplifying the payload concept transition. After drafting the process with a minimum number of basic steps, this work studies the effects of some process parameters to minimize the weight percentage of the matrix while maintaining reasonable mechanical properties. The compressive and the flexural strength are the targets of an orthogonal array Design of Experiment. Through comparison with reference values for civil engineering, the process demonstrates promising results within an organic phase as low as 10 wt%.

The utilization of Fiber Bragg Grating (FBG) sensors in innovative optical sensor networks has displayed remarkable potential in providing precise and dependable thermal measurements in hostile environments on Earth. Multi-Layer Insulation (MLI) blankets serve as critical components of spacecraft and are employed to regulate the temperature of sensitive components by reflecting or absorbing thermal radiation. To enable accurate and continuous monitoring of temperature along the length of the insulative barrier without compromising its flexibility and low weight, FBG sensors can be embedded within the thermal blanket, thereby enabling distributed temperature sensing. This capability can aid in optimizing the thermal regulation of the spacecraft and ensuring the reliable and safe operation of vital components. Furthermore, FBG sensors offer sev eral advantages over traditional temperature sensors, including high sensitivity, immunity to electromagnetic interference, and the ability to operate in harsh environments. These properties make FBG sensors an excellent option for thermal blankets in space applications, where precise temperature regulation is crucial for mission success. Nevertheless, the calibration of temperature sensors in vacuum conditions poses a significant challenge due to the lack of an appropriate calibration reference. Therefore, this paper aimed to investigate innovative solutions for calibrating temperature sensors in vacuum conditions. The proposed solutions have the potential to enhance the accuracy and reliability of temperature measurements in space applications, which can enable engineers to develop more resilient and dependable spacecraft systems.