3DP in Satellites – From Components to the Whole Device

The space industry is in constant need of advanced technology. The driving forces include increased performance requirements, lighter weights, and budget constraints. Additive manufacturing has also emerged as a technology that can design and produce parts at a fast rate. Additionally, 3D printing can produce durable complex parts that can’t be machined or molded, and the technology can print whole assemblies that would otherwise require dozens of individual parts.

Using additive manufacturing, engineers can quickly design, test, and modify components, leading to shorter development cycles and quicker deployment of satellites. This agility is of high value in an industry where technological advancements are rapid and the need for timely deployment is critical.

A number of companies are currently involved in creating satellites via additive manufacturing. Some companies are building the entire satellite with 3D printing, while others are building parts and assemblies.

Producing satellite parts in secret

In the top-secret area of defense equipment, many 3D printing companies are asked to produce parts with no knowledge of how the part is actually going to be used. “We don’t know where the parts we build are going or what they’re doing. We’re probably creating more parts for satellites than we know,” applications engineer Chloe Vollaro from Protolabs told Design News. Vollaro has experience working with a number of satellite companies. “The people building satellites are seeing the same benefits other industries see. You can create complex geometry while also lightweighting the parts. You also don’t have to wait long for each prototype generation.”

Related:Gearing Satellites Up for Space

In building satellites and satellite parts, 3D printing companies work with specialized materials and specific standards that control materials and quality. “We work with the standards AS9100 and AS9102,” said Vollaro.

Protolabs offers a number of services to the satellite industry. “Satellite companies make prototypes with us for validation and information documentation. The low volume they require makes it a good fit for additive manufacturing,” said Vollaro. “3D printing is not always cheaper than machining the part, but if the part is complex, additive manufacturing is a good alternative.”

In recent years, Protolabs has seen a shift from just  prototyping. Satellite companies are now seeking production parts as well as prototyping. “We’re seeing more actual production of parts because industries are gaining a better understanding of when to use 3DP for production,” said Vollaro. “Something that would ordinarily be machined may be better with 3D printing once people understand how additive fits in with their production parts.”

Related:Low-Earth-Orbit Satellites Must Minimize Astronomical Interference

Part of that shift comes down to familiarity. Additive manufacturing is no longer the new-kid-on-the-block when it comes to producing parts. “People are getting more comfortable with the idea of additive manufacturing production,” said Vollaro. “People ask us for the same nondestructive testing that you see in machining. They can test the parts and see that the part is strong, durable and it is not expensive.”

Here's a look at 3D printing for satellites

Markforged used its industrial 3D printers to build a satellite with Sidus Space. The goal was weight reduction, cost reduction, and reduced lead time on new parts. Markforged created the satellite components with aerospace certified Onyx FR-A and Carbon Fibre FR-A materials. By using additive manufacturing, Sidus Space was able to rapidly modify their designs and reduce weight for critical tolerances while stringent standards.

Here's a description of the collaboration:

This satellite will 3D print itself in space. Archinaut One is a satellite that Redwire is building that can 3D print itself in space.

Related:The 3DP Satellite Market Will Hit $1B by 2034

TRUMPF has developed additive manufacturing satellite applications.

Rocket Lab uses 3D printing to produce small, high-performance propulsion engines for its microsatellites. These compact satellites, manufactured at lower cost thanks to additive manufacturing, offer an economical and versatile alternative to traditional space missions.

Fleet Space, an Australian satellite developer, expects to soon launch fully 3D printed satellites. The company is producing a constellation of satellites called Alpha. Additive manufacturing has enabled Fleet Space to design satellites with enhanced connectivity capabilities. This video offers the details: