CSEM develops a 3D printed thermal control system for satellites

CSEM, in collaboration with Thales Alenia Space and Lisi Aerospace Additive Manufacturing, has created an innovative 3D printed pipe segment for advanced thermal management systems in satellites. The part was displayed at the LISI Aerospace booth during the Paris Air Show.

Satellite systems face extreme temperature fluctuations in the harsh environment of geostationary Earth orbit, 35,786 kilometers above the equator. Satellites rely on mechanically pumped loops (MPLs) to maintain optimal operating conditions and transfer heat from hot spots to cold zones. CSEM’s newly developed 3D printed pipe segment significantly enhances MPL functionality by combining heating and in-situ temperature sensing into a single, integrated component.

The stainless steel pipe ensures continuous operation in demanding conditions, is designed to withstand temperatures ranging from -65°C to +85°C, and handles ammonia pressure at 48 bars. The segment uses built-in electrical wires, designed with additive manufacturing techniques, to provide uniform heat transfer around the tube—an improvement over conventional film heaters limited to localized heating.

“The wires’ arrangement ensures optimum heat transfer all around the tube,” explained Hervé Saudan, Group Leader of Precision Mechanisms at CSEM and coordinator of the AHEAD project. “This approach eliminates the risk of delamination or cable disconnection, often encountered with bonded film heaters and traditional sensors.”

The pipe segment leverages high-precision laser powder bed fusion (LPBF) technology to integrate heating elements, sensors, and connectors into a single 3D printed structure. This manufacturing method simplifies MPL installation by eliminating complex bonding and wiring processes, reducing risks and enhancing reliability.

The concept’s feasibility required overcoming significant challenges, including 3D printing long, thin electrical wires that remain electrically insulated from the pipe structure. This was achieved through a unique design involving sacrificial bridges, which are removed after insulation is cured. Saudan and his colleague Lionel Kiener filed a patent protecting the innovative design and manufacturing process.

Initially developed for satellite systems, the 3D printed pipe segment has potential applications in terrestrial IoT and Industry 4.0, where integrated heating and monitoring solutions can improve efficiency and reliability in thermal management processes.