Advancing Spacecraft Thermal Management with 3D Printed Solutions
Slice of Manufacturing Team
Jun 09, 2025
Key highlights
- 3D Systems collaborates with Penn State, Arizona State, and NASA on advanced spacecraft thermal management projects.
- 3D printed titanium heat pipe radiators are 50% lighter and more efficient than current models.
- Nickel titanium (nitinol) shape memory alloy radiators offer a 6× larger deployed-to-stowed area ratio than existing solutions.
Notable Quotes
“ Our long-standing R&D partnership with 3D Systems has enabled pioneering research for the use of 3D printing for aerospace applications. The collective expertise in both aerospace engineering and additive manufacturing is allowing us to explore advanced design strategies that are pushing the boundaries of what is considered state-of-the-art. ”
Alex Rattner, Associate Professor at The Pennsylvania State University
“ Thermal management in the space environment is an ideal application for our DMP technology. These latest projects... demonstrate the potential of our DMP technology to create lightweight, functional parts that advance the state-of-the-art in thermal management for spacecraft applications. ”
Dr. Mike Shepard, Vice President, Aerospace & Defense at 3D Systems
Why This Matters
Thermal management is a critical challenge in space exploration, where extreme temperature variations can jeopardize mission success. The collaboration between 3D Systems, Penn State, Arizona State, and NASA Glenn Research Center is delivering transformative solutions through Direct Metal Printing (DMP) technology and advanced materials.
By embedding porous structures and using shape memory alloys, these innovations promise lighter, more efficient, and self-deploying radiators, which can significantly enhance satellite performance, extend mission lifespans, and reduce launch costs. These breakthroughs not only advance the aerospace sector but also demonstrate additive manufacturing's growing potential across industries like automotive and high-performance computing.
