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NASA 3D-Printed Antenna Takes Additive Manufacturing to New Heights


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NASA 3D-Printed Antenna Takes Additive Manufacturing to New Heights

Field testing was performed at NASA’s Columbia Scientific Balloon Facility in Palestine, Texas, prior to liftoff. To do this, the 3D-printed magneto-electric dipole antenna was mounted to a ladder.
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.

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 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 magneto-electric dipole antenna was mounted to a ladder.
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

Kendall Murphy

Technical Writer

Kendall 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
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      617-496-7998
      mwatzke@cfa.harvard.edu
      Corinne Beckinger
      Marshall Space Flight Center, Huntsville, Alabama
      256-544-0034
      corinne.m.beckinger@nasa.gov
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      Last Updated Aug 20, 2025 EditorLee MohonContactCorinne M. Beckingercorinne.m.beckinger@nasa.gov Related Terms
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    • By NASA
      From top left to right, NASA astronauts Victor Glover, Artemis II pilot; Reid Wiseman, Artemis II commander; CSA (Canadian Space Agency) astronaut Jeremy Hansen, Artemis II mission specialist, and NASA astronaut Christina Koch, Artemis II mission specialist, suit up and walk out of the Neil A. Armstrong Operations and Checkout Building at NASA’s Kennedy Space Center in Florida on Aug. 11.Credit: NASA/Kim Shiflett Lee esta nota de prensa en español aquí.
      NASA is opening media accreditation for multi-day events to introduce America’s newest astronaut class and provide briefings for the Artemis II crewed test flight around the Moon. The activities will take place in September at the agency’s Johnson Space Center in Houston.
      After evaluating more than 8,000 applications, NASA will debut its 2025 class of astronaut candidates during a ceremony at 12:30 p.m. EDT on Monday, Sept. 22. Following the ceremony, the candidates will be available for media interviews.
      The astronaut selection event will stream live on NASA+, Netflix, Amazon Prime, NASA’s YouTube channel, and the agency’s X account.
      The selected candidates will undergo nearly two years of training before they graduate as flight-eligible astronauts for agency missions to low Earth orbit, the Moon, and ultimately, Mars.
      Next, NASA will host a series of media briefings on Tuesday, Sept. 23, and Wednesday, Sept. 24, to preview the upcoming Artemis II mission, slated for no later than April 2026. The test flight, a launch of the SLS (Space Launch System) rocket and Orion spacecraft, will send NASA astronauts Reid Wiseman, Victor Glover, and Christina Koch, along with CSA (Canadian Space Agency) astronaut Jeremy Hansen, on an approximately 10-day mission around the Moon.
      Artemis II will help confirm the systems and hardware needed for human deep space exploration. This mission is the first crewed flight under NASA’s Artemis campaign and is another step toward new U.S.-crewed missions on the Moon’s surface that will help the agency prepare to send American astronauts to Mars.
      The Artemis II events briefings will stream live on the agency’s YouTube channel and X account. Learn how to watch NASA content through a variety of platforms.
      Following the briefings, NASA will host an Artemis II media day at NASA Johnson on Sept. 24, to showcase mission support facilities, trainers, and hardware for Artemis missions, as well as offer interview opportunities with leaders, flight directors, astronauts, scientists, and engineers.
      Media who wish to participate in person must contact the NASA Johnson newsroom at 281-483-5111 or jsccommu@mail.nasa.gov and indicate which events they plan to attend. Confirmed media will receive additional details about participating in these events. A copy of NASA’s media accreditation policy is available on the agency’s website. Media accreditation deadlines for the astronaut candidate selection and Artemis II events are as follows:
      U.S. media interested in attending in person must RSVP no later than 5 p.m., Wednesday, Sept. 17. International media without U.S. citizenship must RSVP no later than 5 p.m., Wednesday, Sept. 10. Media requesting in-person or virtual interviews with the astronaut candidates, Artemis experts, or the Artemis II crew must submit requests to the NASA Johnson newsroom by Wednesday, Sept. 17. In-person interview requests are subject to the credentialing deadlines noted above.
      Information for the astronaut candidate selection and Artemis II events, including briefing participants, is as follows (all times Eastern):
      Monday, Sept. 22
      12:30 p.m.: 2025 Astronaut Candidate Selection Ceremony
      Tuesday, Sept. 23
      11 a.m.: Artemis II Mission Overview Briefing  
      Lakiesha Hawkins, acting deputy associate administrator, Exploration Systems Development Mission Directorate, NASA Headquarters Charlie Blackwell-Thompson, Artemis launch director, NASA’s Kennedy Space Center in Florida Judd Frieling, lead Artemis II ascent flight director, NASA Johnson Jeff Radigan, lead Artemis II flight director, NASA Johnson Rick Henfling, lead Artemis II entry flight director, NASA Johnson Daniel Florez, test director, Exploration Ground Systems, NASA Kennedy 1 p.m.: Artemis II Science and Technology Briefing
      Matt Ramsey, Artemis II mission manager, NASA Headquarters Howard Hu, Orion Program manager, NASA Johnson Jacob Bleacher, manager, Science, Technology Utilization, and Integration, Exploration Systems Development Mission Directorate, NASA Headquarters Mark Clampin, acting deputy associate administrator, Science Mission Directorate, NASA Headquarters Media who wish to participate by phone must request dial-in information by 5 p.m., Sept. 22, by emailing NASA Johnson’s newsroom.
      Wednesday, Sept. 24
      10 a.m.: Artemis II Crew News Conference
      Reid Wiseman, commander Victor Glover, pilot Christina Koch, mission specialist Jeremy Hansen, mission specialist Media who wish to participate by phone must request dial-in information by 5 p.m., Sept. 23, by emailing NASA Johnson’s newsroom.
      Learn more about how NASA leads human spaceflight efforts at:
      https://www.nasa.gov/humans-in-space
      -end-
      Jimi Russell / Rachel Kraft
      Headquarters, Washington
      202-358-1100
      james.j.russell@nasa.gov / rachel.h.kraft@nasa.gov
      Courtney Beasley / Chelsey Ballarte
      Johnson Space Center, Houston
      281-910-4989
      courtney.m.beasley@nasa.gov / chelsey.n.ballarte@nasa.gov
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      Last Updated Aug 20, 2025 LocationNASA Headquarters Related Terms
      Artemis Artemis 2 Candidate Astronauts Humans in Space Mars View the full article
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