Eaton’s additive manufacturing solution supports new chapter of space flight

Background

In 2015, Eaton played a key role in space-flight history when our hydraulic pump facilitated the launch and successful return landing of a suborbital space vehicle. Based on the success of our pump technology, Eaton was asked to develop hydraulic components for the next project — a much larger and more advanced heavy-lift orbital launch vehicle. Through our innovative contributions to the reusable launch vehicle market, Eaton has showcased our hydraulic power leadership as well as our strengths in additive manufacturing that are leading the way to more advanced and sustainable solutions for space flight.

Challenge

The latest generation of space launch vehicles features reusable first-stage booster rockets that are designed to fly back to earth and land vertically. For the orbital launch vehicle project, Eaton was asked to design hydraulic manifold assemblies to operate the landing gear system, which consists of multiple legs that extend from the vehicle and lock into place shortly before landing.

When compared to conventional passenger aircraft, the launch vehicle is colossal in scale, with components that are much larger and more complex to match its dimensions and power requirements. Recognizing that the vehicle’s landing-gear assemblies would be difficult to produce with traditional machining processes — especially considering the project’s challenging weight and envelope requirements — Eaton’s team devised a more sustainable additive manufacturing solution that not only met the customer’s design specifications but also significantly reduced component weight and material waste.

Solution

Leveraging Eaton’s core strengths in additive manufacturing, our team developed a unique design for hydraulic manifold assemblies by utilizing powder bed fusion (PBF) technology. In addition to designing and creating parts to meet operational requirements, the PBF process provided several advantages for the development team, including more design flexibility, faster turnaround times for prototype units, and reduced costs when compared to subtractive “hog out” processes involving extensive machining.

Result

By successfully developing a new additive manufacturing design standard, Eaton has provided a more efficient, compact, lightweight and costeffective product solution for space applications that was not possible with conventional manufacturing options.

Eaton’s additive process resulted in a 30% reduction in component weight compared to traditional machining and at least a 75% reduction in machining scrap, for a total weight savings of 487 pounds per shipset. Additionally, Eaton’s process enabled a 35% reduction in the design envelope by eliminating tool path requirements associated with subtractive manufacturing.

Eaton’s solution is also beneficial from a sustainability standpoint. In addition to scrap reduction, additive manufacturing requires 33% less energy to produce parts when compared to conventional processes, according to a study published by America Makes. Resulting products are lighter, more efficient and less prone to leakage and failure.

Through our continuing innovations in additive manufacturing, Eaton is powering the next chapter of space flight while enhancing our technologies and capabilities to benefit commercial and military customers.