Solar Impulse
Solar Impulse Relies on SLS Parts from the Appenzell region.
Very often, the limits of what is possible and what technology can achieve seem to disappear. The complex, flow-optimized channels of a cooling system are manufactured additively and allow for the most efficient cooling of batteries.
Every plastic component must absolutely fulfil its function both in terms of optimized weight and energy. Lightweight construction is a top priority.
Batteries high in power density that are used in solar-powered aviation have to be cooled in the most efficient way. In order to do that, cold outside air is inserted into the battery in the most efficient manner. This happens through the additively manufactured laser-sintered cooling channels. The ventilation channels that were manufactured in lightweight construction and with between 0.5 to 0.6-mm wall thickness can no longer be manufactured conventionally. Many functions and flow-optimized channel geometries were integrated into a single component so that the eight totally airworthy ventilation components could only be produced using additive Selective Laser Sintering technology. The requirements for plastic components made from high-strength polyamide are high. Tolerances of only a few 0.1 mm have to be met, the surface needs to be optimized for airflow, and a defined air density is critical. Today, a 33-cm-long laser-sintered air inlet only weighs 129 grams.
Installed ventilation system, right and left side of the nacelle [©Solar Impulse]
Ventilation system manufactured in PA12 additive, wall thickness 0. 5 - 0. 6mm
Efficiency measurement of the ventilation system [©Solar Impulse]
Various additive manufactured parts for different functions in and on the cockpit of the Solar Impulse 2 [©Solar Impulse]
