Additive manufacturing developer 3D Systems is collaborating with researchers from Pennsylvania State University and Arizona State University on two National Aeronautics & Space Administration-sponsored projects seeking alternative thermal-management methods for satellite and spacecraft components. They aim to define processes for printing titanium parts for heat rejection radiators embedded with high-temperature passive heat pipes.
3D Systems Application Innovation Group is contributing its Direct Metal Printing technology and customized materials, plus 3DXpert® software developed by its wholly owned subsidiary Oqton.
“Our long-standing R&D partnership with 3D Systems has enabled pioneering research for the use of 3D printing for aerospace applications,” according to Penn State associate professor Alex Rattner. “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. When we complement this with the software capabilities of 3DXpert as well as the low oxygen environment in 3D Systems’ DMP platform, we are able to produce novel parts in exotic materials that enable dramatically improved performance.”
The heat pipe radiators reportedly 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.
An additional project led by researchers at Penn State University and NASA Glenn Research Center with 3D Systems’ AIG delivered a process to additively manufacture one of the first functional parts using nickel-titanium (NiTi, or 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 will be able raise operating power levels and reduce thermal stress on sensitive components, preventing failures and prolonging satellite service life.
Conventional heat pipes are manufactured with complex processes to form porous internal wick structures that passively circulate fluid for efficient heat transfer. Using 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 by 3D Systems’ DMP technology.
The titanium-water heat pipe radiator prototypes were successfully operated at 230°C and weigh 50% less (3 kg/m2 versus over 6 kg/m2) than the standard unit, 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 developing a 3DP process for 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.
Again, the team used 3DXpert to design the deployable spoke structure of the radiator. This was 3D-printed in nitinol using 3D Systems’ DMP technology. When fastened to a satellite or spacecraft this device can be passively actuated and deployed when heated by fluid from within, so no motors or other conventional actuation is needed.
The passive shape memory alloy radiator developed by the team offers advances with projected deployed-to-stowed area ratio that is six times larger than the current state-of-the-art (12× versus 2×) and 70% lighter (<6 kg/m2 versus 19 kg/m2.)
“3D Systems has decades of leadership developing additive manufacturing solutions to transform the aerospace industry,” according to 3D Systems’ Dr. Mike Shepard, vice president, aerospace & defense. “Thermal management in the space environment is an ideal application for our DMP technology. These latest projects, in collaboration with the teams at Penn State, Arizona State, and NASA Glenn Research Center, 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.”
Shepard continued: “Thermal management is an extremely common engineering challenge and the DMP process can deliver solutions that are effective for many industries including aerospace, automotive, and high-performance computing/AI datacenters.”