| Abstract Scope |
We present a low-power, low-temperature deformation processing technique, termed Bend-Forming, that uses CNC wire bending and snap-fit joints to form net-shaped trusses from spooled wire feedstock. The technique is used to fabricate exemplar structures - an isogrid column, a tetrahedral column, and a doubly curved surface - which together highlight the versatility of the process and suggest its use for in-space manufacturing (ISM). Further, by attaching tape spring stiffeners to each strut of exemplar columns fabricated with Bend-Forming, we demonstrate increased load-carrying and buckling capabilities. A trade study comparing Bend-Forming to other ISM methods such as 3D printing, laser beam welding, and electron beam welding is conducted, and preliminary analyses of its unique challenges are presented. Together these results suggest hierarchical trusses fabricated with Bend-Forming can satisfy strength and stiffness requirements for potential applications as a solar sail frame and as a doubly curved support structure for ELF RF antennas. |