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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
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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
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By NASA
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
A test rover with shape memory alloy spring tires traverses rocky, Martian-simulated terrain.Credit: NASA The mystique of Mars has been studied for centuries. The fourth planet from the Sun is reminiscent of a rich, red desert and features a rugged surface challenging to traverse. While several robotic missions have landed on Mars, NASA has only explored 1% of its surface. Ahead of future human and robotic missions to the Red Planet, NASA recently completed rigorous rover testing on Martian-simulated terrain, featuring revolutionary shape memory alloy spring tire technology developed at the agency’s Glenn Research Center in Cleveland in partnership with Goodyear Tire & Rubber.
Rovers — mobile robots that explore lunar or planetary surfaces — must be equipped with adequate tires for the environments they’re exploring. As Mars has an uneven, rocky surface, durable tires are essential for mobility. Shape memory alloy (SMA) spring tires help make that possible.
Shape memory alloys are metals that can return to their original shape after being bent, stretched, heated, and cooled. NASA has used them for decades, but applying this technology to tires is a fairly new concept.
“We at Glenn are one of the world leaders in bringing the science and understanding of how you change the alloy compositions, how you change the processing of the material, and how you model these systems in a way that we can control and stabilize the behaviors so that they can actually be utilized in real applications,” said Dr. Santo Padula II, materials research engineer at NASA Glenn.
Researchers from NASA’s Glenn Research Center and Airbus Defence & Space pose with a test rover on Martian-simulated terrain.Credit: NASA Padula and his team have tested several applications for SMAs, but his epiphany of the possibilities for tires came about because of a chance encounter.
While leaving a meeting, Padula encountered Colin Creager, a mechanical engineer at NASA Glenn whom he hadn’t seen in years. Creager used the opportunity to tell him about the work he was doing in the NASA Glenn Simulated Lunar Operations (SLOPE) Laboratory, which can simulate the surfaces of the Moon and Mars to help scientists test rover performance. He brought Padula to the lab, where Padula immediately took note of the spring tires. At the time, they were made of steel.
Padula remarked, “The minute I saw the tire, I said, aren’t you having problems with those plasticizing?” Plasticizing refers to a metal undergoing deformation that isn’t reversible and can lead to damage or failure of the component.
“Colin told me, ‘That’s the only problem we can’t solve.’” Padula continued, “I said, I have your solution. I’m developing a new alloy that will solve that. And that’s how SMA tires started.”
From there, Padula, Creager, and their teams joined forces to improve NASA’s existing spring tires with a game-changing material: nickel-titanium SMAs. The metal can accommodate deformation despite extreme stress, permitting the tires to return to their original shape even with rigorous impact, which is not possible for spring tires made with conventional metal.
Credit: NASA Since then, research has been abundant, and in the fall of 2024, teams from NASA Glenn traveled to Airbus Defence and Space in Stevenage, United Kingdom, to test NASA’s innovative SMA spring tires. Testing took place at the Airbus Mars Yard — an enclosed facility created to simulate the harsh conditions of Martian terrain.
“We went out there with the team, we brought our motion tracking system and did different tests uphill and back downhill,” Creager said. “We conducted a lot of cross slope tests over rocks and sand where the focus was on understanding stability because this was something we had never tested before.”
During the tests, researchers monitored rovers as the wheels went over rocks, paying close attention to how much the crowns of the tires shifted, any damage, and downhill sliding. The team expected sliding and shifting, but it was very minimal, and testing met all expectations. Researchers also gathered insights about the tires’ stability, maneuverability, and rock traversal capabilities.
As NASA continues to advance systems for deep space exploration, the agency’s Extravehicular Activity and Human Surface Mobility program enlisted Padula to research additional ways to improve the properties of SMAs for future rover tires and other potential uses, including lunar environments.
“My goal is to extend the operating temperature capability of SMAs for applications like tires, and to look at applying these materials for habitat protection,” Padula said. “We need new materials for extreme environments that can provide energy absorption for micrometeorite strikes that happen on the Moon to enable things like habitat structures for large numbers of astronauts and scientists to do work on the Moon and Mars.”
Researchers say shape memory alloy spring tires are just the beginning.
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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
The Space Shuttle Columbia and Space Shuttle Challenger Memorials are seen after a wreath laying ceremony that was part of NASA’s Day of Remembrance, Thursday, Jan. 26, 2023, at Arlington National Cemetery in Arlington, Virginia. (Credit: NASA) NASA will observe its annual Day of Remembrance on Thursday, Jan. 23, honoring the members of the NASA family who lost their lives in the pursuit of exploration and discovery for benefit of humanity. The event, traditionally held every year on the fourth Thursday of January, remembers the crews of Apollo 1 and the space shuttles Challenger and Columbia.
“On NASA’s Day of Remembrance, we pause to reflect on the bravery, dedication, and selflessness of the extraordinary individuals who pushed the boundaries of exploration and discovery,” said NASA Associate Administrator Jim Free. “Their legacies remind us of the profound responsibility we have to carry their dreams forward while ensuring safety remains our guiding principle.”
Free will lead an observance at 1 p.m. EST at Arlington National Cemetery in Virginia, which will begin with a wreath-laying ceremony at the Tomb of the Unknown Soldier, followed by observances for the Apollo 1, Challenger, and Columbia crews.
Several agency centers also will hold observances for NASA Day of Remembrance:
Johnson Space Center in Houston
NASA Johnson will hold a commemoration at 10 a.m. CST at the Astronaut Memorial Grove with remarks by Center Director Vanessa Wyche. The event will have a moment of silence, a NASA T-38 flyover, taps performed by the Texas A&M Squadron 17, and a procession placing flowers at Apollo I, Challenger, and Columbia memorial trees.
Kennedy Space Center in Florida
NASA Kennedy and the Astronauts Memorial Foundation will host a ceremony at the Space Mirror Memorial at Kennedy’s Visitor Complex at 10 a.m. EST. The event will include remarks from Tal Ramon, son of Israeli astronaut Ilan Ramon, space shuttle Columbia.
Kelvin Manning, deputy director at NASA Kennedy, also will provide remarks during the ceremony, which will livestream on the center’s Facebook page.
Ames Research Center in California’s Silicon Valley
NASA Ames will hold a remembrance ceremony at 1 p.m. PST that includes remarks from Center Director Eugene Tu, a moment of silence, and bell ringing commemoration.
Glenn Research Center in Cleveland
NASA Glenn will observe Day of Remembrance with remarks at 1 p.m. EST from Center Director Jimmy Kenyon followed by wreath placement, moment of silence, and taps at Lewis Field.
Langley Research Center in Hampton, Virginia
NASA Langley will hold a remembrance ceremony with Acting Center Director Dawn Schaible followed by placing flags at the Langley Workers Memorial.
Marshall Space Flight Center in Huntsville, Alabama
NASA Marshall will hold a candle-lighting ceremony and wreath placement at 9:30 a.m. CST. The ceremony will include remarks from Larry Leopard, associate director, and Bill Hill, director of Marshall’s Office of Safety and Mission Assurance.
Stennis Space Flight Center in Bay St. Louis, Mississippi
NASA Stennis and the NASA Shared Services Center will hold a wreath-laying ceremony at 9 a.m. CST with remarks from Center Director John Bailey and Anita Harrell, NASA Shared Services Center executive director.
The agency also is paying tribute to its fallen astronauts with special online content, updated on NASA’s Day of Remembrance, at:
https://www.nasa.gov/dor
-end-
Abbey Donaldson
Headquarters, Washington
202-358-1600
Abbey.a.donaldson@nasa.gov
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Last Updated Jan 16, 2025 LocationNASA Headquarters View the full article
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