Aerospace & Defense Technology - August 2024 - 9

MEMS-Based Accelerometer
to Measure Microgravity for
In-Orbit Manufacturing
T
he ForgeStar® program, from U.K.-based Space Forge,
aims to harness the unique environment of space to
create ultra-pure materials that cannot be replicated
on Earth. The key opportunities lie in producing
high-performance semiconductors and super-alloys with fewer
defects and superior properties, thanks to the low-gravity and
vacuum conditions of space.
Space Forge's ForgeStar satellites will be used to produce
advanced materials such as alloys, proteins and semiconductors
in the ultra-vacuum and microgravity conditions of space.
Manufacturing in low Earth orbit (LEO) has huge potential
across sectors from medicine to advanced electronics. Two
examples - high frequency amplifiers and super alloys - that
Space Forge is focused are described in the next two paragraphs.
High frequency amplifiers: Space Forge already produces
wide and ultra-wide bandgap semiconductors, which are crucial
for high-frequency amplifiers in cell towers. Earth-made semiconductors
often suffer from defects due to atmospheric contamination
and gravity-induced lattice rotations, leading to significant
energy loss. By producing these materials in the
" ultimate cleanroom " of space, there is the opportunity to create
semiconductors with far fewer defects, significantly improving
their thermal conductivity and overall efficiency. This improvement
could halve the energy consumption of cell towers, leading
to substantial CO2 emissions savings.
Super alloys for aircraft turbines: Today's jet engine efficiency
is heavily dependent on the strength and quality of
turbine blade materials. Space Forge aims to produce superior
Aerospace & Defense Technology, August 2024
single crystal alloys and ceramics in space, free from the contamination
and buoyancy effects present on Earth. These
space-made materials could result in turbine blades that are
30-50 percent lighter, translating to a potential - and massive
- 10 percent increase in aircraft efficiency, along with
the substantial fuel and emissions savings that would bring
over the aircraft's lifetime.
The main technical challenge is ensuring the safe and reliable
return of materials produced to Earth. Program goals
include demonstrating the viability of this re-usable satellite
technology and proving that space-made materials can significantly
outperform their Earth-made counterparts. Space Forge
aims to achieve these milestones within the next 12 to 24
months, with a critical test run planned within the next year.
In this LEO environment, accurate microgravity measurement
is critical to the success of the process. The precise measurement
of microgravity conditions within the satellite ensures
that the materials are grown in an environment with minimal
gravitational disturbances, which will enable the creation of
ultra-pure crystals and alloys.
As Space Forge explains, " Silicon Sensing's CAS291 accelerometer
is a crucial component in the ForgeStar-1 avionics bay.
Its small size, low weight, and high accuracy make it ideal for
space applications, where every gram and millimetre of space
matters. Accurate microgravity measurement is essential for
linking the production environment to the quality of the
space-made materials, ensuring they meet the highest standards
for industrial and technological applications. "
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Image: AntonKhrupinArt
https://mobilityengineeringtech.com
Aerospace & Defense Technology - August 2024

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