Application of the Month: NASA Uses 3D Printing to Manufacture More Accessible Antennas

Aerospace is one of the sectors where additive manufacturing has truly left its mark. This includes in telecommunications. Here, 3D printing makes it possible to develop antennas with improved designs and advanced materials. These antennas are essential for data transmission in space missions as they facilitate communication between satellites, probes and the Earth.

Recently, engineers from NASA’s Near Space Network and the Electronics 3D Printing group at Goddard Space Flight Center developed and tested a 3D printed antenna using Fortify’s technology. The project sought to demonstrate low-cost design and manufacturing capabilities for efficient antennas that meet industry requirements. The antenna was evaluated with relay satellites and launched on a weather balloon from NASA’s Columbia Scientific Facility in Palestine, Texas. This development took only three months and represents a milestone in the manufacture of low-cost communication equipment for future space missions.

The antenna in the electromagnetic anechoic chamber at the Goddard Center (photo credits: NASA/Peter Moschetti).

The development of 3D printed antennas has many challenges. Manufacturing antennas using 3D printing is particularly complex due to the need to integrate materials with specific electromagnetic properties and ensure adequate conductivity for signal transmission. Engineers designed an optimized structure for data transmission and used innovative materials. NASA stated that “low electrical resistance, tunable, ceramic-filled polymer material,” which allowed it to improve signal tuning. After design and printing, the antenna was tested with NASA’s relay satellites before being tested at high altitudes aboard a weather balloon.