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Why so serious?

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India is slowly catching up with the world to use 3D printing in building products
By Raghu Krishnan, ET Bureau | Updated: Dec 14, 2018, 07.52 AM IST
  • rocket company. The startup has a design for a semi-cryogenic rocket with a 20-kilonewton (KN) engine that can potentially hurl satellites weighing up to 100 kg into lower earth orbit. To become an Uber of rockets, it is taking an unconventional approach. It plans to 3D print rocket engines.


    Whenever there is demand from customers to carry small satellites into space, it can 3D print the engine and assemble it in a rocket and launch them to space. In three years, Agnikul hopes to bring down the cost of access to space significantly and looks to capture a slice of the growing market for launching small satellites. It is up against intense competition globally, but CEO Srinath Ravichandran says it is worth the challenges
    “Can we take a 1980s’ product and build it for the 21st century? As opposed to engines and tanks that go to orbit, we want to take a relook at the product with electronics and software, and build a smart vehicle that can go to orbit,” says 33-year-old Ravichandran, cofounder of the year-old Agnikul that has been shortlisted by European aerospace company Airbus for its incubator programme. “The key is flexible configuration with quality so we are able to launch on demand. We can build an engine in one or two days. Cost is a big differentiator and we can do this from India.”

    In conventional rockets, the engine is assembled by cutting metal and forged based on specifications. There is wastage of metal and the process is long-drawn. It takes time to build a rocket— say around 45 days for the country’s Polar Satellite Launch Vehicle (PSLV). Indian Space Research Organisation (Isro) is already building a smaller rocket that can be assembled once in three days. It plans to test this next year.

    Ravichandran says there is an opportunity for Agnikul to complement Isro’s strengths. Today, there is a global race by private companies to hurl thousands of small satellites, some as light as 1 kg, called nanosatellites, for applications such as internet access, navigation and weather monitoring. SpaceWorks, a US satellite researcher, estimates over 2,600 nano and microsatellites will be launched by 2023. The latest forecast says nearly 60% of the satellites planned are from private players, as against 40% in the five years to 2016.

    While Agnikul is talking about the future, Isro has already taken baby steps in using 3D-printed components for its spacecraft. Its GSAT-19 satellite carried a component called a feed cluster into space two years ago. Wipro 3D, a unit of Wipro Infrastructure, which worked on the component, says India is slowly emerging as a player in application engineering for 3D-printed components and systems. It is already building other aerospace components for India, including a thruster for a satellite engine. 3D printingas a concept is not new.




    For decades, companies used additive manufacturing to make prototypes of parts and systems in industries such as automobile to validate designs before beginning full-scale manufacturing. However, with the cost of electronics coming down and 3D printer sizes becoming smaller, there has been massive adoption of plastic 3D printing. However, metal 3D printing is still evolving. In aerospace, the global adoption is around a decade old.

    GE, which makes aerospace engines, first began using 3D printing to make components for passenger engines. This year, GE tested a full-fledged turboprop engine using 3D-printed parts. The move helped it reduce the weight of the engine by 45 kg, reduce the total number of moving parts to 12 from over 800, and improve engine efficiency by over 10%. In India, Gas Turbine Research Establishment (GTRE), which is developing the Kaveri engine, 3D printed a plastic replica of the engine model and is exploring making components using additive technology.

    But adoption of 3D printing in the aerospace sector in the country has been slower. In 2015, consulting firm 6Wresearch estimated that the Indian 3D-printer market will reach $79 million by 2021. It added that medical, aerospace and military applications showed promising growth in the country. Yet, India has been late in full-scale adoption of 3D printing in the aerospace sector.

    Team Indus, which was looking to send a rover to the moon, built the wheels using 3D printing, bringing downtime to build and lowering the cost of the rover. Hindustan Aeronautics (HAL) has begun 3D printing components for 25 KN engine after one of its component vendors delayed supply. It is also working on systems for an unmanned aerial vehicle. Isro’s efforts are still nascent but are expected to grow significantly. “If we want to embark larger adoption of 3D printing 7-8 years from now, we have to address it today,” said Dr PV Venkitakrishnan, director, capability building programme office, at Isro. “We have to work with the industry to build capability to meet our demand.”

    So far, Isro has begun using 3D-printed components in spacecraft in small volumes. The industry has to mature to meet its demand for more complex components like in rockets. Units across Isro—in satellite making, deep space missions, and rocket labs—are actively looking at using 3D-printed products. “They not only have to meet the qualification for space applications. It has to be economical that competes in costs with our current process,” said Venkitakrishnan. He added that there are organisations with individual strengths such as in design, process, making the right alloy, or manufacturing.


    “They need to collaborate so that they can work on each other’s strengths.”Isro has in-house 3D printers to produce components and products for validating designs and for use in technology demonstrators. But as it scales up its operations—6-18 launches a year, over 70 satellites for the country’s need, scientific exploration, and launch services for global clients — it is increasingly farming work to private firms.

    “It is an opportunity for indigenising systems,” said Ajay Parikh, head of Wipro 3D. The company, which is building India’s first homegrown 3D metal printer along with the Indian Institute of Science, offers consulting, work on engineering the systems, identifying the right alloys, and testing before deploying with customers. “The end-to-end offering is the sweet spot for us,” Parikh said, adding that there is enough interest among companies and organisations for 3D-printed parts and systems.

    While the process is evolving, the agency still needs a CNC machine for finishing 3D-printed products, he said. Stratasys, a manufacturer of plastic 3D printers and which helped GTRE design a plastic engineering model of the Kaveri engine, says it could produce it in 30 days. This helped its partners and customers understand the complexity of the engine better. “Aerospace industry has been using 3D printing in interiors and other areas.

    We have plastic 3D-printed parts in some Airbus aircraft,” said Rajiv Bajaj, managing director, India and Southeast Asia, for Stratasys. The company is working on a metal 3D printing machine that will be launched soon.
 

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ISRO’s GSLV-F11 to take India’s 35th communication satellite to orbit
The satellite will be placed in its final Geostationary Orbit (GEO) using the onboard propulsion system.

Representational image (File | PTI)
On Wednesday, the Geosynchronous Satellite Launch Vehicle – F11 (GSLV-F11), will undertake its 13th flight carrying the 35th Indian Communication satellite GSAT-7A built by the ISRO. GSAT-7A, the advanced communication satellite, built to provide communication capability to the users in Ku-band over the Indian region, is expected to be a shot in the arm for the Indian Air Force as it would add more air power along with additional strategic communication capabilities to the force. The GSLV-F11, which is getting ready for its seventh flight with Indigenous Cryo stage, will place the 2,250-kg GSAT-7A communication satellite into a geosynchronous transfer orbit. It will be launched from the Second Launch Pad (SLP) at Satish Dhawan Space Centre SHAR, Sriharikota.
The satellite to be placed in the geostationary orbit is expected to help the IAF interconnect with various ground radar stations, airbases and AWACS (Airborne Warning And Control System) aircraft. The GSAT-7A Spacecraft is configured on ISRO’s standard I-2,000 kg (I-2K) Bus. The bus capabilities are fully exploited with respect to accommodation, power generation, thermal management, etc. Most of the functional requirements of the communication payloads and the bus platform systems have been derived from ISRO’s earlier geostationary satellites INSATs / GSATs. GSAT-7A spacecraft is configured as the payload for the GSLV MK-II flight F11.
The satellite will be placed in its final Geostationary Orbit (GEO) using the onboard propulsion system. However, it will take a few days after separation from the launcher to reach its orbital slot. GSLV – F11 is ISRO’s fourth generation launch vehicle with three stages. The four liquid strap-ons and a solid rocket motor at the core form the first stage. The second stage is equipped with high thrust engine using liquid fuel. The Cryogenic Upper Stage forms the third and final stage of the vehicle. The GSAT-7A incorporates chemical propulsion system to provide an operational mission life of a minimum of eight years. Chemical propulsion will be used for orbit raising as well as for on orbit attitude correction operations. Sufficient redundancy is built into the Spacecraft for continued service.
 

Why so serious?

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Why Isro's Gsat-7A launch is important for the Indian Air Force
Surendra Singh and U Tejonmayam | TNN | Updated: Dec 19, 2018, 08:49 IST


HIGHLIGHTS

  • The communication satellite will enable the Indian Air Force (IAF) to interlink different ground radar stations, airbases and AWACS aircraft
  • Gsat-7A will not only interlink all airbases, but it will also boost drone operations
  • It will boost the air force’s network-centric warfare capabilities and enhance its global operations
With the

Indian Space Research Organisation
gearing up to launch

Gsat-7A
communication satellite on Wednesday, TOI's Surendra Singh explains why this satellite is important for the Indian Air Force:

What is the need to launch a dedicated satellite for IAF?


Once GSLV-F11 (GSLV Mk II) rocket launches

Gsat-7A satellite
from the second launchpad at Sriharikota at 4.10 pm on Wednesday in the geo orbit, the communication satellite will enable the Indian Air Force (IAF) to interlink different ground radar stations, airbases and AWACS aircraft. It will boost the air force’s network-centric warfare capabilities and enhance its global operations.





Why is Gsat-7A important for IAF?


Gsat-7A will not only interlink all airbases, but it will also boost drone operations as it will help the force upgrade from existing ground control stations to satellite-control of military unmanned aerial vehicles (UAVs). The transition will boost the range, endurance and flexibility of UAVs. This comes at a time when India is in the process of acquiring American armed Predator-B or Sea Guardian drones, which are high-altitude and long endurance satellite-controlled UAVs that can fire at enemy targets from long distances.


What are the features of Gsat-7A?


Costing around Rs 500-800 crore, the communication satellite is configured on the standard 1-2K Bus with bi-propellant chemical propulsion system for orbit rasing and in-orbit maintenance. Its four solar panels are capable of generating around 3.3 kilowatts of electrical power.


How many dedicated communication satellites

Isro
has launched for the military?


Before the scheduled launch of Gsat-7A, Isro had launched Gsat-7, also called ‘Rukmini’, on September 29, 2013 exclusively for the Navy. ‘Rukmini’ has helped the Navy monitor the Indian Ocean Region (IOR) as the satellite has a nearly 2,000 nautical mile ‘footprint’ and provides real-time inputs to Indian warships, submarines and maritime aircraft. The IAF is also likely to get another satellite Gsat-7C, within a few years that will boost its network-centric operations.


What are the space assets of our Indian military?


India currently possesses around 13 military satellites. Most of these remote-sensing satellites like Cartosat-series and Risat satellites are placed in the near-earth orbit which help in better scanning of the earth. However, some of these military satellites have also been put in the geo orbit. The forces use these satellites for surveillance, navigation and communication purpose. The remote sensing satellites had also helped the military in the surgical strike against Pakistan to destroy terror launchpads.



How many military satellites are there in the world?


Currently, there are 320 military satellites orbiting the earth, with the US owning half of them, followed by Russia and China. Of late, China, considered to be India’s biggest rival, has taken huge strides in developing military assets in space, testing even ASAT (anti-satellite) weapons against “low-earth satellites” in January 2017.
 

Advaidhya Tiwari

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Of late, China, considered to be India’s biggest rival, has taken huge strides in developing military assets in space, testing even ASAT (anti-satellite) weapons against “low-earth satellites” in January 2017.
China tested ASAT in 2017? That is something new
 

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For those who don't like to sit in waiting room, launch is at 4:00 PM.

Open DD news at 3:50 PM.
 

Chinmoy

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ISRO should really work on the commentary section. Especially the hindi one.
 

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