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Traditional satellite structures require stacking mechanical frames, heat dissipation modules, and circuit systems, resulting in bulky designs that are vulnerable to space radiation.
Recently, a research team from Harbin Institute of Technology published a paper in Engineering, proposing a “building block” design method. By combining in-house developed high-temperature 3D printing technology and using PEEK as an adhesive, they successfully integrated four major functions—load-bearing, conductivity, thermal conduction, and radiation shielding—into a single composite material board for the first time.
Tests showed this new structure has 21.5% higher stiffness compared to traditional materials, a thermal conductivity nearly six times higher, and the ability to block 28% of space proton radiation.
A satellite must handle intense rocket vibrations, dissipate heat from electronic devices, and protect instruments from extreme radiation. Traditional designs bolt multiple functional modules together, making the structure complex and heavy.
This is especially problematic for nanosatellites, which are often no larger than a shoebox. Fitting circuits, heat sinks, and radiation shields into such a small volume is a significant challenge.
Lead author Dr. Zhang Yan explained, “It’s like adding a heat sink to a smartphone. Sticking a metal sheet behind the motherboard increases thickness and may interfere with signals.”
Attempts to embed lithium batteries into satellite layers have failed due to the added weight of metal components.
Inspired by 3D printing’s layered manufacturing, the team designed a five-layer composite structure:
Bottom layer: PEEK woven with aluminum wire mesh for enhanced stiffness and radiation shielding
Middle layers: Filled with carbon fiber (for weight reduction) and aluminum blocks (for thermal conduction)
Top layer: Embedded copper wire circuits insulated with silicone pads
Final seal: Encapsulated in pure PEEK
All layers are seamlessly bonded using high-temperature molten PEEK.
This isn’t a simple stack—each layer's thickness was optimized using genetic algorithms. Remarkably, the entire structure is 1% lighter than a pure PEEK panel (160.9g vs. 162.5g).
“It’s like packing a suitcase efficiently—fitting more without adding weight,” said corresponding author Prof. Li Longqiu.
The key lies in a 3D printer capable of “grilling steak and baking cake simultaneously.” Traditional printers can only print plastic or metal separately. This new printer operates in a 500°C chamber, using a coaxial nozzle to extrude both molten PEEK and metal wire/carbon fiber simultaneously.
Aluminum wires soften at high temperatures and bond tightly with plastic, solving the long-standing problem of metal-plastic delamination.
This process results in composite materials with only 1.5% porosity—far better than the 8.6% typical for traditional 3D-printed plastics.
Even under bending stress, embedded circuits in printed satellite panels continue to function. When bent by 4.75mm, LED indicators remained lit—equivalent to a smartphone touchscreen still working after being forcefully bent.
When exposed to 35 MeV proton beams (simulating space radiation), the panel reduced proton penetration depth from 9.35mm to 6.74mm, a 27.9% improvement.
Thermal conductivity was even more impressive: PEEK alone registers at 0.25 W/m·K, while the composite structure reached 1.67 W/m·K—enabling fast heat removal from electronic components.
No more bulky multi-module designs—the team successfully printed a cube satellite prototype with six panels integrating sensors, communication chips, and power modules. Once assembled, it performed temperature and humidity monitoring and cloud data transmission.
According to Prof. Li Longqiu, “Astronauts may one day 3D-print replacement parts directly in space stations using similar technology.”
Despite its advantages, challenges remain. High-temperature printing may cause material property fluctuations, and carbon fiber can break inside the nozzle. The team is developing adaptive temperature control algorithms and plans to test the technology in zero-gravity environments.
This research opens new avenues for lightweight spacecraft design. As one reviewer noted, “This proves 3D printing can not only ‘shape’ but also ‘function’—a critical step in space manufacturing.”
The technology has already been applied to a low-Earth orbit satellite project in China, with in-orbit validation expected in 2025. As deep space missions increase, such “universal armor” may become standard for next-gen spacecraft—positioning China advantageously in the space infrastructure race.
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