Multi-switch waveguide image courtesy of Tesat-Spacecom (above)

Design and manufacture radio frequency (RF) passive hardware with efficient, lightweight 3D printed components to guide, filter, modulate, or amplify communications signals from earth to satellite and back

Airbus' filter on payload detail

When you apply design for additive manufacturing (DfAM) functional design for RF components, you expand your capabilities. This greater design flexibility enables design with dramatically fewer interfaces, resulting in a reduced number of losses and an enhanced performance of the entire RF system. Simplification of complex RF hardware assemblies leads to part count reduction, faster and more efficient assemblies and a streamlined supply chain.

NEW - Further Reduce Mass in Passive RF Hardware

Learn how NEW Certified Scalmalloy (A), a high-strength, corrosion-resistant aluminum that is 40% lighter than titanium, further reduces mass in your components. Benefit from optional, cost-effective standard service for APWORKS Scalmalloy production certification through 3D Systems AIG team.

A 3D printed radio frequency part made from Certified Scalmalloy A

Pushing the Boundaries of RF Passive Hardware Design

  • Airbus Monolithic DMP Part Cutaway

  • Monolithic Design for Reduced Part Count

    Direct metal printing (DMP) has sparked innovation in RF design. Our customers are rethinking entire subsystems and producing them as single monolithic structures. To support these customers in their design evolution, our Application Innovation Group offers services to help them maximize the full potentials and values of our latest technologies and advancements.
  • Martijn's antenna 3different views

  • Reduced Footprint of RF Parts

    A major industry trend is to increase the capacity for multiple beams within a single satellite. Typically weight is seen as the major driver of improvements, but volume is of high importance too. The more compact an RF payload is designed, the more channels can be added, enabling more services. Additionally, the launcher typically sets hard limits on the design volume for telecommunication satellites.
  • illustration of sections of the gpl antenna

    D. Gonzalez-Ovejero, N. Chahat, R. Sauleau, G. Chattopadhyay, S. Maci and M. Ettorre, "Additive Manufactured Metal-Only Modulated Metasurface Antennas," IEEE Transactions on Antennas and Propagation, vol. 66, no. 11, pp. 6106-6114, Nov. 2018

  • Smooth Surface Finish

    Machined surfaces have sharp peaks and troughs, while 3D printed surfaces are made of spheroids melted together for a smooth surface finish, improving electrical conductivity. Additive manufacturing enables the ability to shape a part for more effective signal filtering with an optimized surface topology.

Metasurface Antennas

In collaboration with NASA’s Jet Propulsion Laboratory and the Univ Rennes, CNRS, IETR - UMR 6164, 3D Systems produced several thousand elements of this MTS antenna on a single base plate. Low profile and low mass make this an ideal Ka band antenna type for SmallSats and CubeSats.

Reference: D. González‐Ovejero, O. Yurduseven, G. Chattopadhyay and N. Chahat, “Metasurface Antennas: Flat Antennas for Small Satellites,” in CubeSat Antenna Design , IEEE, 2021, pp.255-313.

  • Semiconductor RF antenna 10mm macro

    Macro view of 10 cm diameter antenna face.

  • Semiconductor RF waveguides base plate

    Integral rectangular waveguides machined into reverse side of base plate

  • Semiconductor RF antenna 10mm macro zoom

    Zoom to central region in 10cm diameter antenna face

  • Semiconductor RF 20x SEM image

    20x SEM image of individual elements

  • The DMP Factory 500 3D printers and modules

    3D Systems & Airbus Defence and Space Create Novel Passive RF Components for First Fully Reconfigurable Satellite

    3D Systems’ AIG designed an end-to-end AM solution – comprising its DMP Factory 500, materials, software, and applications expertise – to deliver fully-qualified processes and components required for the large antenna array.

    Learn more
  • Airbus satellite

    Airbus Deploys Additive Manufacturing for RF Components

    The Airbus Defence and Space manufacturing team in Portsmouth, UK, developed innovative designs for the additive manufacturing (AM) of switch assembly networks with AM consultation and production support from 3D Systems. The radiofrequency (RF) passive hardware is designated for two Eurostar Neo spacecraft that will join the in-orbit fleet of Eutelsat, a major provider of satellite communications services.

    Learn more
  • Airbus' new RF filter

    First Air-Worthy Metal 3D Printed RF Filter Ready for Take-Off

    3D Systems’ facility in Leuven, Belgium, has been using the 3D Systems ProX DMP 320 since the machine was in its beta stages. Successful projects include topological optimization, weight reduction, and parts consolidation for spaceflight-validated parts such as brackets and strut end fittings for telecommunications satellites. The Airbus Defence and Space project was 3D Systems Leuven’s first foray into RF filters.

    Read more
Our company has a strong partnership with 3D Systems and has relied on its team of application engineers to help us bring our most advanced designs to life. Everything from the quality of the parts produced using their printers, through to parts qualification, quality management, and overall project management have helped Airbus Defence and Space maintain its position as an industry leader.
—Stephen Phipps, OneSat antenna program manager, Airbus Defence and Space

More Aerospace and Defense Applications

Thales Bracket Close-Up Aerospace

Lightweight Brackets
Metal 3D Printed DLR Fuel Injector

Propulsion
Investment Casting Patterns for Aerospace Applications Thumbnail

Investment Casting
Laserform Heat Exchanger Closeup for Aerospace

Heat Exchangers
ProX DMP 320 Cooling Mantle

Electric Engine Components
Learn More About Our Solutions for RF Passive Hardware Applications
DMP Factory 350 Duel 3D Printer

DMP Factory 350 and DMP Factory 350 Dual

Scalable, high quality metal AM with integrated powder management

Manufacture metal parts with scalable DMLS with removable build chamber for continuous printing

DMP Factory 500 Solution

Robust, high quality metal AM with integrated powder management

LaserForm AlSi10MG Heat Exchanger

LaserForm AlSi10Mg (A)

Good mechanical properties and good thermal conductivity

3D Systems 3DXpert hero image

3DXpert

All-in-One Integrated Software for Industrial Additive Manufacturing

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  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.
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