Additive Technologies and Materials for the Next‐Generation CubeSats and Small Satellites

Abstract CubeSat and small satellites play a very important role in modern space exploration. Their success and diverse capabilities rely on the development of efficient and compact sub‐systems. This task is not trivial due to multiple challenges posed by their small size and mass, and the solution calls for conceptually new designs for the fabrication and integration of complex miniaturized satellite components. The importance of additive techniques in small satellite manufacturing is steadily increasing as they enable rapid, large‐scale production of sophisticated architectures, such as hollow, webbed parts with a cell‐like structure similar to animal bone, with lower mass and improved functionality. Moreover, these architectures feature higher strength, enhanced heat transfer, and efficient thermal and electromagnetic radiation shielding. When compared to traditional subtractive technologies like cutting and milling, additive manufacturing proves to be more versatile and effective in realizing architectures with an increasing intricacy of shapes, structures, and compositions. The perspective explores the suitability of 3D printing in various satellite production tasks, including the propulsion system components and satellite elements. Looking ahead, the challenges and advantages of integrating 3D printing technology into satellite production, emphasizing the need for continuous development through consolidated, proactive collaborative efforts of many devoted teams are outlined.