An Investigation into the Use of Additively Manufactured Components to Reduce Assembly Part Count and De-Risk Radar System Development Projects

Additive Manufacturing is emerging as a cost-effective alternative to conventional manufacturing techniques for applications requiring: components with complex geometries, assemblies comprising a large number of parts or small productions runs. Cost savings can be realised through reduction in raw material required, reduced manufacture times and removing the need for expensive tooling. A recent design activity at BAE Systems Maritime Services Cowes has identified potential cost benefits to producing Antenna Module Frames using AM techniques for a next generation radar technology demonstrator program. This paper will examine the design development procedure when designing for AM and the specific considerations that must be given to component features. In particular, design for minimum support structure will be considered as this has been identified as the main cost driver in an AM build process.