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By NASA
4 Min Read NASA 3D-Printed Antenna Takes Additive Manufacturing to New Heights
The 3D-printed antenna mounted to a ladder prior to testing at NASA's Columbia Scientific Balloon Facility in Palestine, Texas. Credits: NASA/Peter Moschetti In fall 2024, NASA developed and tested a 3D-printed antenna to demonstrate a low-cost capability to communicate science data to Earth. The antenna, tested in flight using an atmospheric weather balloon, could open the door for using 3D printing as a cost-effective development solution for the ever-increasing number of science and exploration missions.
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NASA developed and tested a 3D-printed antenna to demonstrate a low-cost capability to communicate science data to Earth.NASA/Kasey Dillahay Printing
For this technology demonstration, engineers from NASA’s Near Space Network designed and built a 3D-printed antenna, tested it with the network’s relay satellites, and then flew it on a weather balloon.
The 3D printing process, also known as additive manufacturing, creates a physical object from a digital model by adding multiple layers of material on top of each other, usually as a liquid, powder, or filament. The bulk of the 3D-printed antenna uses a low electrical resistance, tunable, ceramic-filled polymer material.
Using a printer supplied by Fortify, the team had full control over several of the electromagnetic and mechanical properties that standard 3D printing processes do not. Once NASA acquired the printer, this technology enabled the team to design and print an antenna for the balloon in a matter of hours. Teams printed the conductive part of the antenna with one of several different conductive ink printers used during the experiment.
For this technology demonstration, the network team designed and built a 3D-printed magneto-electric dipole antenna and flew it on a weather balloon. [JF1] A dipole antenna is commonly used in radio and telecommunications. The antenna has two “poles,” creating a radiation pattern similar to a donut shape.
Testing
The antenna, a collaboration between engineers within NASA’s Scientific Balloon Program and the agency’s Space Communications and Navigation (SCaN) program, was created to showcase the capabilities of low-cost design and manufacturing.
Following manufacturing, the antenna was assembled and tested at NASA’s Goddard Space Flight Center in Greenbelt, Maryland, in the center’s electromagnetic anechoic chamber.
The anechoic chamber is the quietest room at Goddard — a shielded space designed and constructed to both resist intrusive electromagnetic waves and suppress their emission to the outside world. This chamber eliminates echoes and reflections of electromagnetic waves to simulate the relative “quiet” of space.
To prepare for testing, NASA intern Alex Moricette installed the antenna onto the mast of the anechoic chamber. The antenna development team used the chamber to test its performance in a space-like environment and ensure it functioned as intended.
NASA Goddard’s anechoic chamber eliminates echoes and reflections of electromagnetic waves to simulate the relative “quiet” of space. Here, the antenna is installed on the mast of the anechoic chamber.NASA/Peter Moschetti Once completed, NASA antenna engineers conducted final field testing at NASA’s Columbia Scientific Balloon Facility in Palestine, Texas, before liftoff.
The team coordinated links with the Near Space Network’s relay fleet to test the 3D-printed antenna’s ability to send and receive data.
The team monitored performance by sending signals to and from the 3D-printed antenna and the balloon’s planned communications system, a standard satellite antenna. Both antennas were tested at various angles and elevations. By comparing the 3D-printed antenna with the standard antenna, they established a baseline for optimal performance.
Field testing was performed at NASA’s Columbia Scientific Balloon Facility in Palestine, Texas, prior to liftoff. To do this, the 3D-printed antenna was mounted to a ladder.NASA/Peter Moschetti In the Air
During flight, the weather balloon and hosted 3D-printed antenna were tested for environmental survivability at 100,000 feet and were safely recovered.
For decades, NASA’s Scientific Balloon Program, managed by NASA’s Wallops Flight Facility in Virginia, has used balloons to carry science payloads into the atmosphere. Weather balloons carry instruments that measure atmospheric pressure, temperature, humidity, wind speed, and direction. The information gathered is transmitted back to a ground station for mission use.
The demonstration revealed the team’s anticipated results: that with rapid prototyping and production capabilities of 3D printing technology, NASA can create high-performance communication antennas tailored to mission specifications faster than ever before.
Implementing these modern technological advancements is vital for NASA, not only to reduce costs for legacy platforms but also to enable future missions.
The Near Space Network is funded by NASA’s SCaN (Space Communications and Navigation) program office at NASA Headquarters in Washington. The network is operated out of NASA’s Goddard Space Flight Center in Greenbelt, Maryland.
By Kendall Murphy
NASA’s Goddard Space Flight Center, Greenbelt, Md.
About the Author
Kendall Murphy
Technical WriterKendall Murphy is a technical writer for the Space Communications and Navigation program office. She specializes in internal and external engagement, educating readers about space communications and navigation technology.
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Last Updated Jan 22, 2025 EditorGoddard Digital TeamContactKendall Murphykendall.t.murphy@nasa.govLocationGoddard Space Flight Center Related Terms
Manufacturing, Materials, 3-D Printing Goddard Space Flight Center Scientific Balloons Space Communications & Navigation Program Space Communications Technology Technology Explore More
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By NASA
1 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
If you tell Lauren Best Ameen something is hard and cannot be done, she will likely reply, “Watch me.”
As deputy manager for the Cryogenic Fluid Management Portfolio Project Office at NASA’s Glenn Research Center in Cleveland, Ameen and her team look for innovative ways to keep rocket fuel cold for long-duration missions. Work in this area could be important in enabling astronauts to go to the Moon and Mars.
Watch the NASA Faces of Technology video that highlights her work:
For more information about NASA’s Cryogenic Fluid Management Program, visit this page.
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By NASA
2 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
During the 21st Century Community Learning Centers workshop, after-school educators learn to build the “Move It” student activity from NASA’s Build, Launch and Recover Student Activity Guide.Credit: Kristen Marlatt NASA and the U.S. Department of Education are teaming up to engage students in science, technology, engineering, and math (STEM) education during after-school hours. The interagency program strives to reach approximately 1,000 middle school students in more than 60 sites across 10 states to join the program, 21st Century Community Learning Centers (CCLC).
Members of NASA Glenn Research Center’s Office of STEM Engagement traveled to Lansing, Michigan, last month to participate in a two-day professional development training with local after-school educators and facilitators. The training focused on integrating real-world STEM challenges into the 21st CCLC programs.
After-school educators engage in a student activity from NASA’s Build, Launch, and Recover Student Activity Guide. In this challenge, students become engineers and NASA crawler operators while working in teams to design and build a rubber band-powered model of NASA’s crawler-transporter that can carry the most mass possible the farthest distance without failure. Credit: Kristen Marlatt “By engaging in NASA learning opportunities, students are challenged to use critical thinking and creativity to solve real-world challenges that scientists and engineers may face,” said Darlene Walker, NASA Glenn’s Office of STEM Engagement director. “Through the 21st CCLC program, NASA and the Department of Education aim to inspire the next generation of explorers and innovators through high-quality educational content that ignites curiosity and fosters a joy of learning for students across the country.”
NASA Glenn education specialists will continue to provide NASA-related content and academic projects for students, in-person staff training, program support, and opportunities for students to engage with NASA scientists and engineers.
For more information on NASA Glenn’s STEM Engagement, visit https://www.nasa.gov/glenn-stem/
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NASA Glenn employees donated 11 boxes of new, unwrapped gifts to the Toys for Tots program. Credit: NASA/Sara Lowthian-Hanna NASA’s Glenn Research Center continued a decades-long tradition of participating in the Marine Corps Reserve Toys for Tots program during the 2024 holiday season. On Dec. 9, members of the Marine Corps Reserve (3rd Battalion, 25th Marines) picked up 11 boxes of toys donated by employees from NASA Glenn’s facilities in Cleveland and Sandusky, Ohio.
Marine Corps representatives stand at far left and far right of NASA Glenn’s Associate Director Larry Sivic, left, Center Director Dr. Jimmy Kenyon, center, and Acting Deputy Director Dr. Wanda Peters. Credit: NASA/Sara Lowthian-Hanna The Glenn Veterans Employee Resource Group led the donation drive. The Toys for Tots campaign collects and distributes new, unwrapped toys to less fortunate children in the area for Christmas.
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By NASA
NASA astronaut Victor Glover tests collection methods for ISS External Microorganisms in the Neutral Buoyancy Lab at Johnson Space Center.NASA Astronauts are scheduled to venture outside the International Space Station to collect microbiological samples during crew spacewalks for the ISS External Microorganisms experiment. This investigation focuses on sampling at sites near life support system vents to examine whether the spacecraft releases microorganisms, how many, and how far they may travel.
This experiment could help researchers understand whether and how these microorganisms survive and reproduce in the harsh space environment and how they may perform at planetary destinations such as the Moon and Mars. Extremophiles, or microorganisms that can survive harsh environments, are also of interest to industries on Earth such as pharmaceuticals and agriculture.
Spacecrafts and spacesuits are thoroughly sterilized before missions; however, humans carry their own microbiomes and continuously regenerate microbial communities. It’s important to understand and address how well current designs and processes prevent or limit the spread of human contamination. The data could help determine whether changes are needed to crewed spacecraft, including spacesuits, that are used to explore destinations where life may exist now or in the past.
Learn more about how researchers monitor microbes on the space station.
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