{"id":30390,"date":"2025-01-22T09:31:15","date_gmt":"2025-01-22T08:31:15","guid":{"rendered":"https:\/\/ggba.swiss\/?p=30390"},"modified":"2025-01-22T09:31:16","modified_gmt":"2025-01-22T08:31:16","slug":"csem-develops-a-3d-printed-thermal-control-system-for-satellites","status":"publish","type":"post","link":"https:\/\/ggba.swiss\/en\/csem-develops-a-3d-printed-thermal-control-system-for-satellites\/","title":{"rendered":"CSEM develops a 3D-printed thermal control system for satellites"},"content":{"rendered":"\n

In the harsh environment of geostationary Earth orbit\u201435,786 kilometers above the equator\u2014satellite systems face extreme temperature fluctuations. To maintain optimal operating conditions, satellites rely on Mechanically Pumped Loops (MPLs) to transfer heat from hot spots to cold zones. CSEM<\/a>\u2019s newly developed 3D-printed pipe segment significantly enhances MPL functionality by combining heating and in-situ temperature sensing into a single, integrated component.<\/p>\n\n\n\n

Designed to withstand temperatures ranging from -65\u00b0C to +85\u00b0C and handle ammonia pressurized at 48 bars, the stainless-steel pipe ensures continuous operation in demanding conditions. The segment uses built-in electrical wires, designed with additive manufacturing techniques, to provide uniform heat transfer around the tube\u2014an improvement over conventional film heaters, which are limited to localized heating.<\/p>\n\n\n\n

\u201cThe wires\u2019 arrangement ensures optimum heat transfer all around the tube,\u201d explained Herv\u00e9 Saudan, Group Leader of Precision Mechanisms at CSEM and coordinator of the AHEAD project. \u201cThis approach eliminates the risk of delamination or cable disconnection often encountered with bonded film heaters and traditional sensors.\u201d<\/p>\n\n\n\n

Innovative manufacturing for enhanced integration<\/h4>\n\n\n\n

The pipe segment leverages high-precision laser powder bed fusion (LPBF) technology to integrate heating elements, sensors, and connectors into a single 3D-printed structure. This manufacturing method simplifies MPL installation by eliminating complex bonding and wiring processes, reducing risks and enhancing reliability.<\/p>\n\n\n\n

The concept\u2019s feasibility required overcoming significant challenges, including the 3D printing of long, thin electrical wires that remain electrically insulated from the pipe structure. This was achieved through a unique design involving sacrificial bridges, which are removed after insulation is cured. The innovative design and manufacturing process are protected by a patent filed by Saudan and his colleague Lionel Kiener.<\/p>\n\n\n\n

Initially developed for satellite systems, the 3D-printed pipe segment has potential applications in terrestrial IoT and Industry 4.0, where integrated heating and monitoring solutions can improve efficiency and reliability in thermal management processes.<\/p>\n","protected":false},"excerpt":{"rendered":"

CSEM, in collaboration with Thales Alenia Space and Lisi Aerospace Additive Manufacturing, has created an innovative 3D-printed pipe segment for advanced thermal management systems in satellites.<\/p>\n","protected":false},"author":6,"featured_media":30391,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"mc4wp_mailchimp_campaign":[],"footnotes":""},"categories":[839],"tags":[978,943,903,886,901],"class_list":["post-30390","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tech-en","tag-3d-printing-en","tag-advanced-manufacturing","tag-aerospace","tag-rd","tag-technology-park"],"acf":[],"yoast_head":"\nCSEM develops a 3D-printed thermal control system for satellites<\/title>\n<meta name=\"description\" content=\"CSEM has created an innovative 3D-printed pipe segment for advanced thermal management systems in satellites.\" \/>\n<meta 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