SM5 - Key Techniques in Sustainable Manufacturing

Sustainable Satellite ManufacturinG

UKSA Space Cluster Microcredentials

05

Key Techniques in SUstainable Manufacturing

• Explore Design for Test and Manufacture: Learn about the significance of Design for Test (DFT) and Design for Manufacture (DFM) in sustainable design. Understand how these practices contribute to efficient manufacturing processes and reduced waste.

• Analyse Lifecycle Assessment: Gain knowledge of Lifecycle Analysis (LCA) as a tool for assessing the environmental impact of satellite design and manufacturing throughout its entire lifecycle. Understand how LCA can inform sustainable design decisions.

Learning Objectives

• Definition: Design for Manufacture (DFM) is a product development approach focused on simplifying the manufacturing process. It aims to reduce production costs, enhance product quality, and minimize waste by considering manufacturing constraints and opportunities early in the design phase.
• Objective: The primary goal is to create products that are easy and cost-effective to manufacture without compromising on quality or performance.

Benefits:

• Lower manufacturing costs
• Reduced material waste
• Shorter production times
• Improved product reliability

Design for Manufacture (DFM)

Principles of DFM

Collaboration Between Design and Manufacturing Teams:

• Foster early and ongoing communication between designers and manufacturing engineers to ensure manufacturability and address potential issues in the design phase.

Use of DFM Tools and Software:

• Leverage DFM analysis tools and software to simulate manufacturing processes, identify design inefficiencies, and optimise product designs for manufacturing.

Continuous Improvement:

• Adopt a mindset of continuous improvement, regularly reviewing and refining products and processes to further reduce costs and improve manufacturability.

Implementing DFM Strategies

Definition: Design for Test (DFT) is an engineering approach that integrates testability into the product design process. It aims to make products easier, faster, and more cost-effective to test, ensuring high quality and reliability. Purpose: DFT strategies are employed to identify and correct defects early in the manufacturing process, reducing the need for costly rework or scrap. Benefits:

• Enhanced product reliability and quality
• Reduced testing and debugging time
• Lower manufacturing and warranty costs
• Improved customer satisfaction

Design for Test

Accessibility: Designing products with easy access to test points, ensuring that testing equipment can effectively interface with the product. Observability and Controllability:

• Observability: The ability to observe the internal states of a system through its outputs.
• Controllability: The ability to control the internal states of a system through its inputs.

Built-In Self-Test (BIST):

• Integrating circuits that enable a product to test its own functionality, reducing the need for external testing resources.

Modular Design:

• Creating products with modular components that can be tested independently, simplifying the testing process and isolating defects.

Key Principles of DFT

Early Integration in the Design Process:

• Incorporating DFT considerations early and throughout the product development cycle to maximise testability and minimise redesign efforts.

Collaboration Between Design and Test Engineers:

• Encouraging close collaboration between design engineers and test engineers to identify and address testability challenges from the outset.

Use of DFT Tools and Software:

• Leveraging specialised DFT analysis tools and software to simulate and evaluate the testability of designs before physical prototypes are developed.

Implementing DFT Strategies

DFM

DFT

Issue: The compact and integrated design of satellites limits physical access to test points, complicating the implementation of traditional DFT strategies.Impact: This can lead to increased testing time and complexity, potentially increasing costs.

Issue: The high-tech components required for satellites often have limited suppliers, leading to supply chain vulnerabilities. Impact: Dependency on specialized suppliers can introduce risks related to cost, quality, and delivery timelines

Access and Integration Constraints

Supply Chain Complexity

Issue: Satellites may incorporate the latest technologies, which may not yet have mature, well-understood manufacturing processes. Impact: Incorporating cutting-edge components can complicate manufacturing processes, requiring extensive customization and testing.

Issue: Satellites must withstand extreme conditions, including vacuum, radiation, and thermal extremes. Testing these conditions on Earth requires sophisticated and often custom test setups. Impact: Developing and validating these test environments can be time-consuming and expensive

Environmental Considerations

Integration of Adv Technologies

Issue: Satellites comprise highly complex systems where components must interact flawlessly in space. Ensuring comprehensive test coverage that accounts for all possible interactions and failure modes is challenging.Impact: Inadequate testing can lead to undetected issues that cause mission failure.

Issue: The selection of materials and manufacturing processes is restricted by the need for high reliability and survivability in space. This limits the flexibility to optimize designs purely for ease of manufacture. Impact: These constraints can lead to higher costs and longer lead times.

Complex System Interactions

Material and Process Constraints

Challenges in Satellite Manufacturing

• Innovative Test Design: Develop custom testing tools and methods that can simulate space conditions accurately and offer high observability and controllability within the constraints of satellite designs.

• Early Collaboration: Foster early and continuous collaboration between design engineers, manufacturing teams, and testing departments to identify and address manufacturability and testability issues.

• Modular Design: Utilise modular design principles where possible to simplify both manufacturing and testing processes, allowing for easier integration and fault isolation.

• Supply Chain Management: Develop robust supply chain strategies that include multiple sources for critical components and partnerships with suppliers for co-development efforts.

OvercomING CHallenges

• Design for Test (DFT) and Design for Manufacture (DFM) are methodologies aimed at making products easier to test and manufacture, respectively.
• These practices play a crucial role in sustainable design by ensuring products are built efficiently, with minimal waste and energy consumption.

Key Benefits:

• Reduces resource waste by optimising material use and minimizing scrap.
• Lowers energy consumption during manufacturing processes.
• Enhances product reliability and longevity, reducing the need for frequent replacements and minimizing environmental impact.

DFT and DFM in Sustainable Manufacturing

• Reduced Environmental Footprint: By optimising testing and manufacturing processes, DFT and DFM contribute to significant reductions in waste and energy use, aligning with sustainability goals.

• Economic Benefits: Streamlined production processes lower manufacturing costs, while improved product quality reduces warranty and service costs, enhancing economic efficiency.

• Sustainability Goals Achievement: DFT and DFM are integral to developing products that meet sustainability objectives, offering a pathway to more responsible consumption and production patterns.

Impact OF DFT and DFM in Sustainable Manufacturing

• Lifecycle Assessment (LCA) is a systematic approach to evaluating the environmental impacts associated with all stages of a product's life, from raw material extraction through materials processing, manufacture, distribution, use, repair and maintenance, and disposal or recycling.

• In the context of satellite design and manufacturing, LCA provides insights into how design decisions affect the satellite's environmental footprint throughout its entire lifecycle.

Importance: Understanding the LCA of satellites is crucial for minimizing their environmental impact, optimising resource use, and promoting sustainability in the increasingly important space industry.

Introduction to LCA in Satellite Design & Manufacturing

• Raw Material Extraction and Processing: Analyses the environmental impact of extracting and processing materials used in satellite construction, such as metals, composites, and electronic components.

• Manufacturing and Assembly: Evaluates the energy consumption, emissions, and waste generated during the manufacturing and assembly of satellite components and the complete satellite.
• Launch Operations: Assesses the environmental impact of launch operations, including rocket propellant emissions and the potential for space debris.
• Operation in Space: Considers the satellite's operational efficiency, use of energy in space, and the potential for generating space debris during its mission.
• End-of-Life Management: Examines the environmental implications of satellite deorbiting, disposal, or recycling strategies, focusing on minimising space debris and ensuring sustainable use of orbital space.

Key Stategs of LCA

Informed Design Decisions:

• Material Selection: Choosing materials with lower environmental impacts during extraction, processing, and end-of-life disposal.
• Energy Efficiency: Designing satellites to operate with minimal energy consumption, utilizing solar power and other sustainable energy sources.
• Minimising Waste: Implementing design for disassembly and recycling principles to reduce waste at the end of the satellite's life.

Benefits:

• Reduces the environmental footprint of satellite missions.
• Promotes the sustainability of space activities.
• Informs stakeholders, including regulators, customers, and the public, about the environmental considerations of satellite projects.

Applying LCA for Sustainable Satellite Design

Challenges:

• Data Availability: Obtaining accurate and comprehensive data on material sourcing, manufacturing processes, and the long-term impact of satellites in space.
• Complexity of Space Operations: Accounting for the unique challenges of space, such as varying orbital lifetimes and the potential for creating long-lasting space debris.

Opportunities:

• Innovation in Sustainable Materials: Researching and adopting new materials and technologies that reduce the environmental impact of satellites.
• Advancements in End-of-Life Strategies: Developing innovative solutions for satellite deorbiting and recycling to mitigate space debris and promote sustainability.

Challenges & Opportunities in LCA

Assessment Tools and Methods:

• Sustainability Reports: Review publicly available sustainability reports or environmental impact statements provided by the company.
• Certifications and Standards: Look for adherence to international sustainability standards and certifications (e.g., ISO 14001, LEED, SA8000).
• Third-Party Evaluations: Consider assessments from independent organizations or industry watchdogs that evaluate company practices.

Key Indicators of Sustainability:

• Reduction in greenhouse gas emissions over time.
• Percentage of recycled materials used in manufacturing.
• Initiatives for reducing energy consumption and waste.
• Employee welfare programs and community engagement efforts.
• Transparency and reporting on sustainability goals and achievements.

Evaluating Sustainability Practices

Strategic Implications:

• Partnerships: Choose to partner with companies that demonstrate a strong commitment to sustainability, aligning with corporate social responsibility goals.
• Investment: Direct investments towards companies with sustainable practices, minimizing environmental and social risks.
• Regulatory Compliance: Ensure that the company's operations comply with existing and upcoming environmental regulations, reducing legal and reputational risks.

Identifying and evaluating the sustainability of satellite manufacturing companies involves a comprehensive assessment of their environmental, social, and economic practices. By utilising a range of tools and indicators, stakeholders can make informed decisions that promote the long-term sustainability of the space industry and contribute to broader environmental and social objectives

Making Informed Decisions Based on Sustainability Evaluations

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