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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
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
A crane lowers the steel reflector framework for Deep Space Station 23 into position Dec. 18 on a 65-foot-high (20-meter) platform above the antenna’s pedestal that will steer the reflector. Panels will be affixed to the structure create a curved surface to collect radio frequency signals.NASA/JPL-Caltech After the steel framework of the Deep Space Station 23 reflector dish was lowered into place on Dec. 18, a crew installed the quadripod, a four-legged support structure that will direct radio frequency signals from deep space that bounce off the main reflector into the antenna’s receiver.NASA/JPL-Caltech Deep Space Station 23’s 133-ton reflector dish was recently installed, marking a key step in strengthening NASA’s Deep Space Network.
NASA’s Deep Space Network, an array of giant radio antennas, allows agency missions to track, send commands to, and receive scientific data from spacecraft venturing to the Moon and beyond. NASA is adding a new antenna, bringing the total to 15, to support increased demand for the world’s largest and most sensitive radio frequency telecommunication system.
Installation of the latest antenna took place on Dec. 18, when teams at NASA’s Goldstone Deep Space Communications Complex near Barstow, California, installed the metal reflector framework for Deep Space Station 23, a multifrequency beam-waveguide antenna. When operational in 2026, Deep Space Station 23 will receive transmissions from missions such as Perseverance, Psyche, Europa Clipper, Voyager 1, and a growing fleet of future human and robotic spacecraft in deep space.
“This addition to the Deep Space Network represents a crucial communication upgrade for the agency,” said Kevin Coggins, deputy associate administrator of NASA’s SCaN (Space Communications and Navigation) program. “The communications infrastructure has been in continuous operation since its creation in 1963, and with this upgrade we are ensuring NASA is ready to support the growing number of missions exploring the Moon, Mars, and beyond.”
This time-lapse video shows the entire day of construction activities for the Deep Space Station 23 antenna at the NASA Deep Space Network’s Goldstone Space Communications Complex near Barstow, California, on Dec. 18. NASA/JPL-Caltech Construction of the new antenna has been under way for more than four years, and during the installation, teams used a crawler crane to lower the 133-ton metal skeleton of the 112-foot-wide (34-meter-wide) parabolic reflector before it was bolted to a 65-foot-high (20-meter-high) alidade, a platform above the antenna’s pedestal that will steer the reflector during operations.
“One of the biggest challenges facing us during the lift was to ensure that 40 bolt-holes were perfectly aligned between the structure and alidade,” said Germaine Aziz, systems engineer, Deep Space Network Aperture Enhancement Program of NASA’s Jet Propulsion Laboratory in Southern California. “This required a meticulous emphasis on alignment prior to the lift to guarantee everything went smoothly on the day.”
Following the main lift, engineers carried out a lighter lift to place a quadripod, a four-legged support structure weighing 16 1/2 tons, onto the center of the upward-facing reflector. The quadripod features a curved subreflector that will direct radio frequency signals from deep space that bounce off the main reflector into the antenna’s pedestal, where the antenna’s receivers are housed.
In the early morning of Dec. 18, a crane looms over the 112-foot-wide (34-meter-wide) steel framework for Deep Space Station 23 reflector dish, which will soon be lowered into position on the antenna’s base structure.NASA/JPL-Caltech Engineers will now work to fit panels onto the steel skeleton to create a curved surface to reflect radio frequency signals. Once complete, Deep Space Station 23 will be the fifth of six new beam-waveguide antennas to join the network, following Deep Space Station 53, which was added at the Deep Space Network’s Madrid complex in 2022.
“With the Deep Space Network, we are able to explore the Martian landscape with our rovers, see the James Webb Space Telescope’s stunning cosmic observations, and so much more,” said Laurie Leshin, director of JPL. “The network enables over 40 deep space missions, including the farthest human-made objects in the universe, Voyager 1 and 2. With upgrades like these, the network will continue to support humanity’s exploration of our solar system and beyond, enabling groundbreaking science and discovery far into the future.”
NASA’s Deep Space Network is managed by JPL, with the oversight of NASA’s SCaN Program. More than 100 NASA and non-NASA missions rely on the Deep Space Network and Near Space Network, including supporting astronauts aboard the International Space Station and future Artemis missions, monitoring Earth’s weather and the effects of climate change, supporting lunar exploration, and uncovering the solar system and beyond.
For more information about the Deep Space Network, visit:
https://www.nasa.gov/communicating-with-missions/dsn
News Media Contact
Ian J. O’Neill
Jet Propulsion Laboratory, Pasadena, Calif.
818-354-2649
ian.j.oneill@jpl.nasa.gov
2024-179
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Last Updated Dec 20, 2024 Related Terms
Deep Space Network Jet Propulsion Laboratory Space Communications & Navigation Program Space Operations Mission Directorate Explore More
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By European Space Agency
Video: 00:10:27 In 1975, 10 European countries came together with a vision to collaborate on key space activities: science and astronomy, launch capabilities and space applications: the European Space Agency, ESA, was born.
In 2025, we mark half a century of joint European achievement – filled with firsts and breakthroughs in science, exploration and technology, and the space infrastructure and economy that power Europe today.
During the past five decades ESA has grown, developing ever bolder and bigger projects and adding more Member States, with Slovenia joining as the latest full Member State in January.
We’ll also celebrate the 50th anniversary of ESA’s Estrack network, 30 years of satellite navigation in Europe and 20 years since ESA launched the first demonstration satellite Giove-A which laid the foundation for the EU’s own satnav constellation Galileo. Other notable celebrations are the 20th anniversary of ESA’s Business Incubation Centres, or BICs, and the 30th year in space for SOHO, the joint ESA and NASA Solar and Heliospheric Observatory.
Sadly though, 2025 will mean end of science operations for Integral and Gaia. Integral, ESA's gamma-ray observatory has exotic objects in space since 2002 and Gaia concludes a decade of mapping the stars. But as some space telescopes retire, another one provides its first full data release. Launched in 2023, we expect Euclid’s data release early in the new year.
Launch-wise, we’re looking forward to Copernicus Sentinel-4 and -5 (Sentinel-4 will fly on an MTG-sounder satellite and Sentinel-5 on the MetOp-SG-A1 satellite), Copernicus Sentinel-1D, Sentinel-6B and Biomass. We’ll also launch the SMILE mission, or Solar wind Magnetosphere Ionosphere Link Explorer, a joint mission with the Chinese academy of science.
The most powerful version of Europe’s new heavy-lift rocket, Ariane 6, is set to fly operationally for the first time in 2025. With several European commercial launcher companies planning to conduct their first orbital launches in 2025 too, ESA is kicking off the European Launcher Challenge to support the further development of European space transportation industry.
In human spaceflight, Polish ESA project astronaut Sławosz Uznański will fly to the ISS on the commercial Axiom-4 mission. Artemis II will be launched with the second European Service Module, on the first crewed mission around the Moon since 1972.
The year that ESA looks back on a half century of European achievement will also be one of key decisions on our future. At the Ministerial Council towards the end of 2025, our Member States will convene to ensure that Europe's crucial needs, ambitions and the dreams that unite us in space become reality.
So, in 2025, we’ll celebrate the legacy of those who came before but also help establish a foundation for the next 50 years. Join us as we look forward to a year that honours ESA’s legacy and promises new milestones in space.
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By NASA
As the agency continues to explore for the benefit of all, NASA is in the process of searching for a new headquarters facility in Washington or the immediate surrounding area.
The current NASA Headquarters lease expires in August 2028, and the agency already has evaluated multiple options including leasing or purchasing within the District of Columbia. Through a request for information published Thursday, NASA took a small step in a longer process to determine the best outcome for the agency and U.S. taxpayers.
“With a new facility on the horizon, NASA has a unique opportunity to better meet the needs of a new generation of explorers, discoverers, and public servants – the Artemis Generation,” said Bob Gibbs, associate administrator, Mission Support Directorate. “The next NASA Headquarters will reflect our journey in a facility that inspires and engages the public, aligns with new ways of working, fosters innovation and connection, and maximizes taxpayer funding.”
NASA is asking for responses from members of the development community, local and state jurisdictions, academia, other federal agencies, commercial aerospace partners, and other interested parties to help inform its decision.
Needs for a new headquarters includes approximately 375,000 to 525,000 square feet of office space to house NASA’s workforce. The desired location is within walking distance to a Washington Metropolitan Area Transit Authority station. In addition, the new location also needs parking options, as well as convenient access to food establishments.
Other ideal characteristics for a new setting include the capability to renovate the space to create a dynamic, flexible, and adaptive work environment inclusive of open work areas, enclosed offices, open collaboration areas, teaming rooms, conference rooms, sensitive compartmented information facilities, and secured storage spaces, to include potential stakeholder meeting, Science, Technology, Engineering, and Mathematics (STEM) educational outreach, and storage spaces.
Responses to the request for information are due no later than 12 p.m. EST on Jan. 15, 2025. This call for ideas is for informational purposes only and is intended to assist NASA with its planning and strategic decisions regarding a future facility. It is not a request for a lease proposal or a solicitation for a contract or other agreement, and it does not obligate NASA in any way.
Under the leadership of the administrator, NASA Headquarters provides overall guidance and direction to the agency, through 10-field centers and a variety of installations nationwide.
To learn more about NASA and its missions, visit:
https://www.nasa.gov
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Last Updated Nov 14, 2024 LocationNASA Headquarters Related Terms
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By European Space Agency
This September saw the completion of a critical milestone for the construction of ESA's new deep space communication antenna in New Norcia, Australia: the lifting of the 122-tonne reflector dish.
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