Modular product design for additive manufacturing of satellite components: maximising product value using genetic algorithms

For space manufacturers, additive manufacturing promises to dramatically reduce weight and costs by means of integral designs achieved through part consolidation. However, integrated designs hinder the ability to change and service components over time - actually increasing costs - which is instead enabled by highly modular designs. Finding the optimal trade-off between integral and modular designs in additive manufacturing is of critical importance. In this article, a product modularisation methodology is proposed for supporting such trade-offs. The methodology is based on combining function modelling with optimisation algorithms. It evaluates product design concepts with respect to product adaptability, component interface costs, manufacturing costs and cost of post-processing activities. The developed product modularisation methodology is derived from data collected through a series of workshops with industrial practitioners from three different manufacturer companies of space products. The implementation of the methodology is demonstrated in a case study featuring the redesign of a satellite antenna.