Case Study: ETHM (Thales Alenia Space’s Electrical Thruster Mechanism) achieves 0.1° pointing accuracy and lightweight, production-ready design with 3D Systems

Design and Additive Manufacturing Expertise from 3D Systems to Serve Thales Alenia Space Satellite Sub-System

3D Systems partnered with Thales Alenia Space to redesign a mission‑critical Electrical Thruster Mechanism (ETHM) for the Spacebus NEO satellite. The ETHM—made up of seven additively manufactured brackets—needed to fit a tight 480×480×380 mm envelope, minimize mass, reduce part count by integrating harnesses and piping, and meet stringent orbital‑class performance and repeatability requirements including 0.1° pointing accuracy.

3D Systems’ Application Innovation Group provided DfAM expertise, manufacturability guidance, print‑file preparation in 3DXpert, and a validated manufacturing flow (CNC finishing, 100% tomography, CMM inspection) while producing >70 units at its Customer Innovation Center. Parts are printed in LaserForm Ti6Al4V Grade 23 and production was transferred to Thales’ Morocco facility via technology transfer. The result is a compact, topologically optimized ETHM that achieves the 0.1° accuracy, reduces mass to improve thruster and fuel efficiency, and supports repeatable series production with rigorous quality control (up to 249 inspection points).

ETHM

Gilles Lubrano

Product Manager