AEROSPACE. Designed for the extreme conditions DESIGN MANUFACTURING INTEGRATION ELECTRICAL HARNESS (MLI) BLANKETS MULTI LAYER INSULATION

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2 Designed for the extreme conditions PASSIVE THERMAL CONTROL ELECTRICAL SUB-SYSTEM AEROSPACE DESIGN MANUFACTURING INTEGRATION MULTI LAYER INSULATION (MLI) BLANKETS ELECTRICAL HARNESS

3 About us Since its beginning Aviotec supported Thales Alenia Space Italy in MLI and MDPS manufacturing for ISS Programs starting from Node 3 and Cupola. Today, Aviotec is a specialized company involved in design and manufacturing of: MLI blankets for Spacecraft s Passive Thermal Control System Micrometeroid and Debris Protection System bumpers Manned Spacecraft s internal items as: Cargo Transfer Bag Rack Internal Belts Nomex Mesh Net Electrical Harness for Spacecraft and Aircraft application

4 Manufacturing Area The Aviotec manufacturing facilities are divided in two separated areas. One is for the Electrical Harness and the second one is dedicated for the Multi Layer Insulation blankets. Both areas are under environmental control concerning: contamination, humidity and temperature. The cleanliness level stays within ISO Class 8 particles concentration. The requirements are maintained under control by the monitoring of 0,5µm, 1µm and 5µm particle size using a TSI AEROTRAK particle counter. MFG Electrical Harness Area MFG Multi Layer Insulation Area AEROTRAK Particle Counter

5 Background Experience The High-Quality of the Aviotec s products is ensured by the experience acquired in several Space programs as: NODE 3 MDPS Bumpers CUPOLA MLI Blankets PMM MDPS Bumpers ATV MLI Blankets and MDPS bumpers Electrical Harness Flight Model Unit 5 CYGNUS PCM MLI blankets and MDPS bumpers Electrical Harness Flight Model Unit 3 PRISMA PAYLOAD MLI Blankets FLPP IXV Mock-up for electrical harness manufacturing Electrical Harness Flight Model Unit

6 Node3 & Cupola NODE3 (2008) Manufacturing of Microeteorite and Debris Protection System (MDPS) composed of kapton nomex, nextel and kevlar layers. CUPOLA (2008) we built Multi-layer insulation composed by aluminized beta cloth and kapton nomex. PMM (Permanent Multipurpose Module) ex Leonardo MPLM: PMM In 2009, Aviotec produces MDPS (Meteorite and Debris Protection System) for shielding improvement to satisfy the new requirement and stay additional 10 years in orbit with ISS. Bags & Belts Customer: ISS Cargo Transfer Bags ISS Retaining Belts

7 Automated Transfer Vehicle Manufacturing of MLI blankets & MDPS Customer:

8 Automated Transfer Vehicle Manufacturing of MLI blankets & MDPS Customer:

9 CYGNUS PRESSURIZED CARGO MODULE Manufacturing of MLI blankets & MDPS Customer:

10 Prisma Payload Design & Manufacturing of MLI blankets Customer:

11 Design and Development process on CATIA V5 Starting from Spacecraft structure 3D model step file and Thermal Requirement Specification delivered by the Customer, Aviotec develops the MLI blankets. The design is focused to obtain the MLI blankets shape taking into account the minimization of thermal leaks, definition of fasteners points and grounding, as well as easy mounting and dismounting of the blankets for accessibility to required areas. On the basis of the 3D shape, Aviotec prepares the 2D Master Template Tool for MLI blankets Manufacturing.

12 Design & MFG Flow

13 Design & 3D Model STEP file (Input from customer) MFG Flow MLI blankets 3D Model Design (Catia V5) Manufacturing 2D Template Tool Blanket Manufactured Hardware

14 AVIOTEC PERFORM CRIMPING OPERATIONS IN ACCORDANCE WITH ESA ECSS-ST-Q-70-26C ELECTRICAL HARNESS EVERY CRIMPING S TOOLS ARE CALIBRATED AND SEALED DEDICATED STRIPPERS FOR EACH TYPE OF SPACE WIRE CONTROL PROCESS TEST GO NO-GO GAUGE DAILY CHECK MICRO-SECTION ELECTRICAL TEST CHECKER: TENSILE STRENGTH EVERY 100 CRIMPING OPERATION FOR EACH TOOL VOLTAGE DROP TEST INSULATION CONTINUITY

15 ELECTRICAL HARNESS GALLERY ESA CIRCULAR CONNECTOR BASED ON MIL-C SERIES III CRIMPING - ESA ECSS-Q-ST-70-26C IXV HARNESS BUNDLE IXV PDU HARNESS 3D HARNESS ROUTING HARNESS DURING MANUFACTURING

16 FLPP IXV FLIGHT MODEL ELECTRICAL HARNESS MANUFACTURING Customer: IXV MOCK-UP IN AVIOTEC CLEAN ROOM MANUFACTURING OF HARNESS ON MOCK-UP BUILT BY AVIOTEC

17 NASA PROJECT: RECYCLE FOR LIVING Customer: ISS CARGO TRANSFER BAG STANDARD FORWARD OSMOSIS CTB INTERNAL BAG PLUMBING LAYOUT UNFOLDED CTB INCORPORATED INTO WALL ELEMENTS SUCH AS DIVIDERS AND A CHAIR AVIOTEC PROTOTYPE BAG IN AVIOTEC CLEAN ROOM INTERNAL LAYOUT SOLUTION POCKET FOR FORWARD OSMOSIS MEMBRANE

18 AEROSPACE QUALITY AVIOTEC Quality Management System is certificated EN 9100:2009 and ISO 9001:2008 with the following scope: DESIGN, PRODUCTION AND INTEGRATION OF MULTI LAYER INSULATION BLANKETS (MLI) FOR AEROSPACE APPLICATION. PRODUCTION OF ELECTRICAL HARNESS FOR AEROSPACE APPLICATION. PRODUCTION OF FABRIC ARTICLES FOR AEROSPACE APPLICATION. The manufacturing process of MLI envisages the following on-ground validation activities: VERIFYING OF INCOMING DOCUMENTATION AND CHECKING THE REPRODUCTION SCALE OF MASTER TEMPLATE: analysis of the specifications and drawings for preparation of worksheet checking the dimensional deviations by measuring the X and Y ruler indicators on master template and recording the values MATERIALS ACCEPTANCE AND STORAGE: incoming inspection and acceptance report recording in company s database software of all material traceability features identification of materials through ID tags and Q.C. stamp MLI MANUFACTURING: Preparation of material kit according to part list recording of material traceability features (p/n and batch number) in dedicated worksheet of MLI internal multilayer preparation according to part list and recording in Multilayer Preparation Sheet (MPS) recording of all operations step by step and related Q.C. inspection during MLI manufacturing MLI FINAL ACCEPTANCE: Notice to the customer and final Quality Inspection (MIP) MLI IDENTIFICATION LABEL: Application of ID label made of kapton reporting P/N and S/N according to customer CIDL PACKAGING: Double bag in anti-static nylon and hygroscopic salts MLI collocation in Transport Container and Shipping to the customer DOCUMENTATION DELIVERED FOR EACH MLI: Worksheet with recording data of: P/N and Batch Number of material used Stamp of Date and ID operator step by step for all operation Stamp of Quality Inspector ID step by step for all operation Weight Electrical conductivity test report Check List of all inspection performed during MIP Certificate of Conformity

19 EVENTS: PARIS, LE BOURGET AIR SHOW 2013 ILA BERLIN AIR SHOW FARNBOROUGH AIRSHOW JUNE MAY 2012 JULY 2012 AEROSPACE & DEFENSE MEETINGS TORINO OCTOBER 2013

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