Mynaric turns to APWORK for serial AM of Condor MK3 components

APWORKS and the laser communication specialist Mynaric collaborated to produce a titanium fork structure that has been 3D printed using the EOS M400-4 system. The structure was implemented in the Mynaric Condor Mk3 Optical Communications Terminal—an advanced laser optical terminal designed for satellite and other aerospace platforms that require secure communication links.

The Condor Mk3 has proven to be a flagship product for Mynaric, playing a critical role in establishing robust, high-performance optical communication in space and other high-demand environments. Essential to the success of this terminal is the precision and durability of the components that make up its internal architecture, particularly the titanium gimbal fork, which has been serially manufactured by APWORKS using metal LPBF technology.

Leveraging the German service provider’s unique know-how of metal AM, APWORKS and Mynaric teams collaborated to refine the fork’s design, ensuring it meets the stringent technical requirements of aerospace applications, particularly in terms of thermal stability and stiffness. The design itself was optimized for the additive manufacturing process, resulting in a structure that is not only lightweight but also ideally suited to the constraints and capabilities of LPBF.

One of the key achievements of this collaboration was the development of a nesting strategy that allows four forks to be built simultaneously on the same build platform, with each fork assigned its own dedicated laser. This approach significantly improves the throughput and cost-efficiency of production, pushing additive manufacturing into the realm of economically viable serial production. Alongside the main components, numerous test specimens are printed to ensure consistent quality and verify that the mechanical properties align with the original design specifications.

After the printing process is complete, the build platform undergoes heat treatment in a vacuum furnace to relieve internal stresses that naturally develop during the melting process. The parts are then carefully removed from the platform using wire electro-discharge machining (EDM), followed by a thorough manual post-processing phase that includes visual and dimensional inspections. Critical interfaces are precision-machined to meet tight tolerances, ensuring seamless integration of the component into the final product.

Once the titanium forks pass APWORKS’ final inspection, they are shipped to Mynaric, where they undergo additional steps including painting, assembly, and integration into the Condor Mk3 system. This end-to-end process has already yielded over 100 successfully produced and delivered components, proving not just the technical feasibility but also the economic viability of using metal additive manufacturing for high-performance aerospace parts.