3D Systems enables advanced thermal control systems research
In collaboration with Penn State University, Arizona State University, and NASA
3D Systems, an industry-leading 3D printing company, is collaborating with researchers from Penn State University and Arizona State University on two NASA-sponsored projects aimed at redefining thermal management in space. These projects tackle the extreme temperature fluctuations that can compromise sensitive spacecraft components, a leading cause of mission failure.
Leveraging its Direct Metal Printing (DMP) technology, tailored materials, and Oqton’s 3DXpert software, 3D Systems is helping engineer next-generation heat rejection systems for satellites and exploratory spacecraft.
One project—spearheaded by Penn State, Arizona State, and NASA Glenn Research Center in collaboration with 3D Systems’ Application Innovation Group—focuses on titanium-based heat pipe radiators. Additively manufactured with embedded high-temperature passive heat pipes, these components are 50% lighter and operate at higher temperatures than current solutions, improving heat radiation in high-power systems.
The second initiative, led by Penn State and NASA Glenn, pushes even further by producing one of the first functional parts in nickel-titanium (nitinol) shape memory alloy (SMA). These radiators deploy passively when heated, eliminating the need for motors or actuators in space. The SMA radiator’s deployed-to-stowed area ratio is 6× greater than conventional solutions, a leap forward for CubeSats and small-scale missions.
Traditionally, heat pipes require complex manufacturing to create internal wick structures. Here, the research team embedded a porous network directly into the pipe walls using 3DXpert software and printed them monolithically in titanium and nitinol using DMP. The titanium-water heat pipes functioned reliably at 230°C and weighed just 3 kg/m²—half the weight of standard models—meeting NASA’s performance and cost-to-launch benchmarks.
The SMA radiators offer equally transformative gains: 70% lighter (<6 kg/m² vs. 19 kg/m²) and a 12× deployed-to-stowed area ratio. Their shape-memory behavior allows them to activate with internal fluid heat, enabling actuation-free deployment.
“Our long-standing R&D partnership with 3D Systems has enabled pioneering research for the use of 3D printing for aerospace applications,” said Alex Rattner, associate professor at Penn State.
3D Systems has already delivered over 2,000 structural components and 200 passive RF parts currently in flight, with hardware integrated into more than 15 active satellites.
