In space applications, flexible hinges are most commonly used in instrument mechanisms, e.g., for precise rotation of mirrors in a limited angular range, but also for the deployment of appendages and deployable booms, as so called collapsible flexible hinges. Further advantages are, e.g., no need for assembly due to single-piece manufacturing, no friction losses, no need for lubrication due to lack of joints, and no wear by erosion due to lack of physical contact between kinematic pairs. They are used in industrial or space applications, where high reliability, accuracy, and demanding requirements to contamination apply. Finally, a qualified flexure pivot has been manufactured in a hybrid manner to subsequently ensure its long-term durability in a lifetime test bench.įlexural pivots, flexible element hinges or compliant mechanisms are devices that connect or transmit loads between two components by elastically deflecting in an allowable range. As a result, the gained knowledge was applied for the AM-specific redesign of the flexure pivot. Furthermore, quantitative image analysis, mechanical testing, laser scanning microscopy, and 3D shape measurement of manufactured specimens were conducted.

Moreover, a profound characterization of the powder morphology and flowability was carried out using scanning electron microscopy (SEM) and novel rheological investigation techniques.

Due to its major impact on the process, the chemical powder composition was characterized in detail by energy dispersive X-ray spectroscopy (EDX) and inductively coupled plasma optical emission spectrometry (ICP-OES). As a contribution to part qualification, the manufacturing process, powder material, and fabricated specimens were investigated in a comprehensive manner. Frictionless flexure pivot bearings are used in space mechanisms that require high reliability, accuracy, and technical cleanliness. Within this contribution, the additive manufacturing of filigree flexure pivots using 316L-Si by means of LMD with powder is presented. Moreover, the advantages aforementioned combined with conventional machining enable novel manufacturing approaches in various fields of applications. Compared to the well-known powder bed fusion process, LMD enhances manufacturing possibilities to overcome AM-specific challenges such as process inherent porosity, minor build rates, and limited part size.

Recently, additive manufacturing (AM) by laser metal deposition (LMD) has become a key technology for fabricating highly complex parts without any support structures.

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