3D Systems' Additive Manufacturing Solutions Enable Pioneering Research on Advanced Thermal Control Systems for Next Generation Space Missions

Published: 2025-06-03 11:23:07 ET DDD

Published on 06/03/2025 at 11:23

* 3D Systems' applications expertise, technologies foundational to research projects led by Penn State, Arizona State & NASA Glenn Research Center

* Additive manufacturing enabling novel titanium and nitinol passive heat pipes for space applications with 50% reduced weight enabling more efficient thermal management

* Researchers advance state-of-the-art for thermal management of CubeSats with projected 6× greater deployed-to-stowed-area ratio with one of the first additively manufactured shape memory alloy (nitinol) radiators

* 3D Systems' solutions accelerating the adoption of additive manufacturing use in space applications - a total addressable market anticipated to reach nearly $4 billion by 2030

ROCK HILL, South Carolina - Today, 3D Systems (NYSE: DDD) announced the Company is collaborating with researchers from Penn State University and Arizona State University on two projects sponsored by the National Aeronautics & Space Administration (NASA) intended to enable ground-breaking alternatives to current thermal management solutions. Severe temperature fluctuations in space can damage sensitive spacecraft components, resulting in mission failure. By combining deep applications expertise with 3D Systems' leading additive manufacturing (AM) solutions comprising Direct Metal Printing (DMP) technology and tailored materials and Oqton's 3DXpert® software, the teams are engineering sophisticated thermal management solutions for the demands of next-generation satellites and space exploration. The project led by researchers with Penn State University, Arizona State University, and the NASA Glenn Research Center[1] in collaboration with 3D Systems' Application Innovation Group (AIG) has resulted in processes to build embedded high-temperature passive heat pipes in heat rejection radiators that are additively manufactured in titanium. These heat pipe radiators are 50% lighter per area with increased operating temperatures compared with current state-of-the-art radiators, allowing them to radiate heat more efficiently for high power systems. Additionally, a project led by researchers at Penn State University and NASA Glenn Research Center[2] with 3D Systems' AIG yielded a process to additively manufacture one of the first functional parts using nickel titanium (nitinol) shape memory alloys that can be passively actuated and deployed when heated. This passive shape memory alloy (SMA) radiator is projected to yield a deployed-to-stowed area ratio that is 6× larger than currently available solutions, enabling future high-power communications and science missions in restricted CubeSat volume. When deployed on spacecraft, such as satellites, these radiators can raise operating power levels and reduce thermal stress on sensitive components, preventing failures and prolonging satellite lifespan.

Traditionally, heat pipes have been manufactured with complex processes to form porous internal wick structures that passively circulate fluid for efficient heat transfer. Using Oqton's 3DXpert® software, the Penn State/Arizona State/NASA Glenn/3D Systems project team embedded an integral porous network within the walls of the heat pipes, avoiding subsequent manufacturing steps and resulting variability. Monolithic heat pipe radiators were manufactured in titanium and nitinol on 3D Systems' DMP technology. The titanium-water heat pipe radiator prototypes were successfully operated at temperatures of 230°C and weigh 50% less (3 kg/m2 versus over 6 kg/m2), meeting NASA goals for heat transfer efficiency and reduced cost to launch for space-based applications.

The Penn State/NASA Glenn/3D Systems team is also pushing the boundaries of what is possible with metal AM by developing a process to 3D print passively deployed radiators with shape memory alloys. The chemistry of these materials can be tuned to change shape with application of heat. SMAs can withstand repeated deformation cycles without fatigue and exhibit excellent stress recovery. The team again used 3DXpert to design the deployable spoke structure of the radiator. This was then 3D printed in nitinol (NiTi), a nickel-titanium shape memory alloy, using 3D Systems' DMP technology. When affixed to a spacecraft such as a satellite, this device can be passively actuated and deployed when heated by fluid inside, thus removing the need for motors or other conventional actuation in space. The passive shape memory alloy radiator developed by the team offers transformative advances with projected deployed-to-stowed area ratio that is 6× larger than what is currently considered state-of-the-art (12× versus 2×) and 70% lighter (