In a joint project with Penn State University, Arizona State University and the NASA Glenn Research Center, 3D Systems is working on new concepts for heat dissipation in space systems. With the help of additive manufacturing, titanium and nitinol components are being created that are specifically tailored to the requirements of small satellites (CubeSats). The focus is on passive radiators with reduced weight and improved performance.
Temperature management is a key challenge in space missions. Electronic systems require stable thermal conditions in order to function reliably. Conventional radiators and heat pipes reach their limits with small installation spaces and changing thermal loads. Additive manufacturing now enables the production of functionally integrated components that meet both structural and thermal requirements. Additive manufacturing now enables the production of functionally integrated components that meet both structural and thermal requirements.
“Our long-standing research and development partnership with 3D Systems has enabled groundbreaking advances in aerospace 3D printing,” said Alex Rattner, associate professor at Pennsylvania State University. “Our combined expertise in aerospace engineering and additive manufacturing allows us to develop advanced design strategies that redefine the state of the art. By combining 3DXpert’s software capabilities with 3D Systems’ low-oxygen DMP environment, we can produce novel parts from exotic materials that offer significantly improved performance.”
As part of the research projects, heat pipes with integrated porous capillary structures were manufactured directly in titanium for the first time. This eliminates the need for subsequent processing steps. According to 3D Systems, a prototype made of titanium weighs only around half as much as conventional components, while at the same time withstanding temperatures of up to 230 °C. The shape memory alloy Nitinol is also used: in another project, a radiator was developed that unfolds automatically when heated. The resulting larger surface area improves heat radiation without having to use mechanical actuators.
“3D Systems has been a leader in developing additive manufacturing solutions to transform the aerospace industry for decades,” said Dr. Mike Shepard, Vice President, Aerospace & Defense, 3D Systems. “Thermal management in space is an ideal application for our DMP technology. These recent projects in collaboration with the Penn State, Arizona State and NASA Glenn Research Center teams demonstrate how our DMP technology is developing lightweight, functional parts that advance the state of the art in thermal management for spacecraft. Thermal management is an extremely common engineering challenge. This is where the DMP process can deliver solutions that are effective for many industries such as aerospace, automotive and high-performance computing/AI data centers.”
The additively manufactured components are expected to contribute to the thermal stabilization of communication and scientific satellites in the future and also offer potential for other industries with high performance requirements, such as data centers or aviation applications.
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