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Completed TRL 6 (started at 4, targeting 6)
This project intends to address a critical bottleneck in the implementation of 3D printed electronics for the unique and demanding environment of spaceflight. The primary challenge lies in the cumbersome process of translating conventional electronic designs, typically conceived for planar substrates, into toolpaths that can be effectively utilized by additive manufacturing systems. This translation often involves intermediary steps using Computer-Aided Manufacturing (CAM) software, which can introduce distortions and limit the design freedom necessary to fully leverage the potential of 3D printing, particularly when dealing with complex, non-planar geometries.
The current industry standard involves converting a customer's Computer-Aided Design (CAD) model into a CAM representation. This process often projects the 2D design onto a 3D surface, leading to length distortions and necessitating applicable post-processing. This indirect approach hinders the ability to directly print electronics onto unconventional Generative Design (GD) structures, which hold significant promise for optimizing the mass, structural integrity, and functionality of spaceflight hardware and astrophysics detectors.
Ultimately, the success of this project will be measured by the development of a single source software capable of importing and creating unique surface structures and, critically, enabling the design of electronics directly on those complex surfaces. This software must incorporate all the conventional electronics design features found in existing specialized software, providing NASA engineers with a comprehensive and intuitive platform for creating advanced 3D printed hybrid electronic systems for future spaceflight applications. The ability to directly design and print electronics on complex geometries will unlock significant advancements in miniaturization, weight reduction, and functional integration, ultimately enhancing the capabilities and efficiency of space-based technologies.
The key benefit for NASA is a proven workflow for designing and fabricating 3D printed electronics on complex surfaces, eliminating distortion-prone conversion processes. The Creo plugin enables direct design on curved geometries, facilitating integration with generative design and optimizing hardware for spaceflight. This leads to potential advancements in weight reduction and functional integration, enhancing the capabilities and efficiency of space-based circuitry developed by NASA engineers.
Listed on TechPort itself — the most direct way to ask about this specific project.
This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.
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