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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
NASA’s Jet Propulsion Laboratory used radar data taken by ESA’s Sentinel-1A satellite before and after the 2015 eruption of the Calbuco volcano in Chile to create this inter-ferogram showing land deformation. The color bands west of the volcano indicate land sinking. NISAR will produce similar images.ESA/NASA/JPL-Caltech A SAR image — like ones NISAR will produce — shows land cover on Mount Okmok on Alaska’s Umnak Island . Created with data taken in August 2011 by NASA’s UAVSAR instrument, it is an example of polarimetry, which measures return waves’ orientation relative to that of transmitted signals.NASA/JPL-Caltech Data from NASA’s Magellan spacecraft, which launched in 1989, was used to create this image of Crater Isabella, a 108-mile-wide (175-kilometer-wide) impact crater on Venus’ surface. NISAR will use the same basic SAR principles to measure properties and characteristics of Earth’s solid surfaces.NASA/JPL-Caltech Set to launch within a few months, NISAR will use a technique called synthetic aperture radar to produce incredibly detailed maps of surface change on our planet.
When NASA and the Indian Space Research Organization’s (ISRO) new Earth satellite NISAR (NASA-ISRO Synthetic Aperture Radar) launches in coming months, it will capture images of Earth’s surface so detailed they will show how much small plots of land and ice are moving, down to fractions of an inch. Imaging nearly all of Earth’s solid surfaces twice every 12 days, it will see the flex of Earth’s crust before and after natural disasters such as earthquakes; it will monitor the motion of glaciers and ice sheets; and it will track ecosystem changes, including forest growth and deforestation.
The mission’s extraordinary capabilities come from the technique noted in its name: synthetic aperture radar, or SAR. Pioneered by NASA for use in space, SAR combines multiple measurements, taken as a radar flies overhead, to sharpen the scene below. It works like conventional radar, which uses microwaves to detect distant surfaces and objects, but steps up the data processing to reveal properties and characteristics at high resolution.
To get such detail without SAR, radar satellites would need antennas too enormous to launch, much less operate. At 39 feet (12 meters) wide when deployed, NISAR’s radar antenna reflector is as wide as a city bus is long. Yet it would have to be 12 miles (19 kilometers) in diameter for the mission’s L-band instrument, using traditional radar techniques, to image pixels of Earth down to 30 feet (10 meters) across.
Synthetic aperture radar “allows us to refine things very accurately,” said Charles Elachi, who led NASA spaceborne SAR missions before serving as director of NASA’s Jet Propulsion Laboratory in Southern California from 2001 to 2016. “The NISAR mission will open a whole new realm to learn about our planet as a dynamic system.”
Data from NASA’s Magellan spacecraft, which launched in 1989, was used to create this image of Crater Isabella, a 108-mile-wide (175-kilometer-wide) impact crater on Venus’ surface. NISAR will use the same basic SAR principles to measure properties and characteristics of Earth’s solid surfaces.NASA/JPL-Caltech How SAR Works
Elachi arrived at JPL in 1971 after graduating from Caltech, joining a group of engineers developing a radar to study Venus’ surface. Then, as now, radar’s allure was simple: It could collect measurements day and night and see through clouds. The team’s work led to the Magellan mission to Venus in 1989 and several NASA space shuttle radar missions.
An orbiting radar operates on the same principles as one tracking planes at an airport. The spaceborne antenna emits microwave pulses toward Earth. When the pulses hit something — a volcanic cone, for example — they scatter. The antenna receives those signals that echo back to the instrument, which measures their strength, change in frequency, how long they took to return, and if they bounced off of multiple surfaces, such as buildings.
This information can help detect the presence of an object or surface, its distance away, and its speed, but the resolution is too low to generate a clear picture. First conceived at Goodyear Aircraft Corp. in 1952, SAR addresses that issue.
“It’s a technique to create high-resolution images from a low-resolution system,” said Paul Rosen, NISAR’s project scientist at JPL.
As the radar travels, its antenna continuously transmits microwaves and receives echoes from the surface. Because the instrument is moving relative to Earth, there are slight changes in frequency in the return signals. Called the Doppler shift, it’s the same effect that causes a siren’s pitch to rise as a fire engine approaches then fall as it departs.
Computer processing of those signals is like a camera lens redirecting and focusing light to produce a sharp photograph. With SAR, the spacecraft’s path forms the “lens,” and the processing adjusts for the Doppler shifts, allowing the echoes to be aggregated into a single, focused image.
Using SAR
One type of SAR-based visualization is an interferogram, a composite of two images taken at separate times that reveals the differences by measuring the change in the delay of echoes. Though they may look like modern art to the untrained eye, the multicolor concentric bands of interferograms show how far land surfaces have moved: The closer the bands, the greater the motion. Seismologists use these visualizations to measure land deformation from earthquakes.
Another type of SAR analysis, called polarimetry, measures the vertical or horizontal orientation of return waves relative to that of transmitted signals. Waves bouncing off linear structures like buildings tend to return in the same orientation, while those bouncing off irregular features, like tree canopies, return in another orientation. By mapping the differences and the strength of the return signals, researchers can identify an area’s land cover, which is useful for studying deforestation and flooding.
Such analyses are examples of ways NISAR will help researchers better understand processes that affect billions of lives.
“This mission packs in a wide range of science toward a common goal of studying our changing planet and the impacts of natural hazards,” said Deepak Putrevu, co-lead of the ISRO science team at the Space Applications Centre in Ahmedabad, India.
Learn more about NISAR at:
https://nisar.jpl.nasa.gov
News Media Contacts
Andrew Wang / Jane J. Lee
Jet Propulsion Laboratory, Pasadena, Calif.
626-379-6874 / 818-354-0307
andrew.wang@jpl.nasa.gov / jane.j.lee@jpl.nasa.gov
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Last Updated Jan 21, 2025 Related Terms
NISAR (NASA-ISRO Synthetic Aperture Radar) Earth Earth Science Earth Science Division Jet Propulsion Laboratory Explore More
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By NASA
Freelancer NASA’s Sustainable Business Model Challenge is looking for entrepreneurs, startups, and researchers to leverage the agency’s publicly available Earth system science data to develop commercial solutions for climate challenges.
This opportunity, with a submission deadline of June 13, bridges the gap between vast climate data and actionable solutions by inviting solvers to transform data into sustainable business models that support climate resilience and decision-making.
“Creative, outcome-driven entrepreneurs are the lifeblood of our country’s economy, and we’re excited to see the sustainable climate solutions they’re able to come up with when working closely with NASA’s vast resources and data,” said Jason L. Kessler, program executive for the NASA Small Business Innovation Research / Small Business Technology Transfer (SBIR/STTR) program, which is sponsoring the challenge.
Through the Sustainable Business Model Challenge, NASA aims to foster a new set of sustainable enterprises capable of turning climate insights into tangible market-ready services, ultimately contributing to a more resilient future for vulnerable communities, businesses, and ecosystems. NASA is committed to broadening participation in its solicitations and fostering technology advancements.
By engaging new entrepreneurs, the challenge serves as a pathway to NASA’s SBIR/STTR program, helping scale solutions to advance the global response to climate change and encourage a more sustainable future. From its vantage point in space, NASA holds a wealth of data that can inform new approaches to climate adaptation and mitigation.
Participants will submit a 10-page business concept paper that includes details on how they will incorporate NASA climate or Earth system data to deliver a product or service. Up to ten winning teams will receive $10,000 each, along with admission to a 10-week capability development training designed to strengthen any future proposals for potential NASA funding.
NASA’s SBIR/STTR program, managed by the agency’s Space Technology Mission Directorate, is part of America’s Seed Fund, the nation’s largest source of early-stage funding for innovative technologies. Through this program, entrepreneurs, startups, and small businesses with less than 500 employees can receive funding and non-monetary support to build, mature, and commercialize their technologies, advancing NASA missions and advancing the nations aerospace economy.
Ensemble is hosting the challenge on behalf of NASA. The NASA Tournament Lab, part of the Prizes, Challenges, and Crowdsourcing program in the Space Technology Mission Directorate, manages the challenge. The program supports global public competitions and crowdsourcing as tools to advance NASA research and development and other mission needs.
The deadline to participate in NASA’s Sustainable Business Model Challenge is June 13, 2025.
For more information about the challenge, visit: https://nasabusinesschallenge.org/
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By NASA
Trailer for NASA’s upcoming documentary, “Planetary Defenders,” which will take audiences inside the high-stakes world of asteroid hunting and planetary defense. NASA is bringing the high-stakes world of planetary defense to the Sundance Film Festival, highlighting its upcoming documentary, “Planetary Defenders,” during a panel ahead of its spring 2025 premiere on the agency’s streaming service.
“We’re thrilled that NASA is attending Sundance Film Festival for the first time – a festival renowned for its innovative spirit,” said Brittany Brown, director, NASA Office of Communications Digital and Technology Division, at the agency’s Headquarters in Washington. “Our participation represents a groundbreaking opportunity for NASA to engage with the film industry and share new avenues for collaborative storytelling. By connecting with the creative minds at the festival, we aim to inspire new narratives, explore new avenues for collaborative storytelling, and ignite a renewed sense of wonder in space exploration.”
The NASA+ film explores a compelling question: How would humanity respond if we discovered an asteroid headed for Earth? Far from science fiction, “Planetary Defenders” follows real-life astronomers and other experts as they navigate the challenges of asteroid detection and safeguarding our planet from potential hazards.
“NASA is home to some of the greatest stories ever told, and NASA’s new streaming platform NASA+ is dedicated to sharing these stories to inspire the next generation,” said Rebecca Sirmons, general manager and head of NASA+. “We are honored to host a panel at this year’s Sundance Film Festival discussing our upcoming NASA+ documentary “Planetary Defenders.”
The panel, entitled “You Bet Your Asteroid: NASA Has a Story to Tell,” will start at 1:30 p.m. MST on Sunday, Jan. 26, at the Filmmaker Lodge in the Elks Building, 550 Main St., 2nd Floor, Park City, Utah. The event will include a discussion about the film followed by a Q&A session. Attendees also will have the opportunity to meet NASA experts and some of the planetary defenders themselves.
Panelists include:
Rebecca Sirmons, head of NASA+, NASA Scott Bednar, filmmaker and director, NASA 360/National Institute of Aerospace Jessie Wilde, filmmaker and director, NASA 360/National Institute of Aerospace Dr. Kelly Fast, acting planetary defense officer, NASA’s Planetary Defense Coordination Office David Rankin, senior survey operations specialist, Catalina Sky Survey Dr. Vishnu Reddy, professor of planetary sciences and director of the Space4 Center, University of Arizona Media are encouraged to RSVP in advance and may request one-on-one interviews with NASA experts following the panel by contacting Karen Fox at karen.c.fox@nasa.gov.
Through NASA+, the agency is continuing its decades long tradition of sharing live events, original content, and the latest news while NASA works to improve life on Earth through innovation, exploration, and discovery for the benefit of all. The free, on-demand streaming service is available to download without a subscription on most major platforms via the NASA App on iOS and Android mobile and tablet devices, as well as streaming media players like Roku, Apple TV, and Fire TV.
To keep up with the latest news from NASA’s planetary defense program, visit:
https://www.nasa.gov/planetarydefense
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Abbey Donaldson
Headquarters, Washington
202-358-1600
abbey.a.donaldson@nasa.gov
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Last Updated Jan 17, 2025 EditorJessica TaveauLocationNASA Headquarters Related Terms
NASA+ Asteroids Planetary Defense Planetary Defense Coordination Office Planetary Science Planetary Science Division Science Mission Directorate Social Media View the full article
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