Tracking Space Weather with 3D Printed Fluxgate Magnetometer Sensors

We propose developing a breakthrough capability to 3D print miniaturized single-axis fluxgate magnetometers within ceramic structures, enabling large-scale, consistent manufacturing of science-grade sensors for space weather monitoring. This innovation addresses current production bottlenecks in GSFC's Miniaturized Science Magnetometer (MSM) by replacing labor-intensive hand assembly with streamlined additive manufacturing. Partnering with Marshall Space Flight Center, we will print ceramic structures with embedded metal coils, ensuring precision and reproducibility of four key design features: (1) wire thickness, (2) turn spacing, (3) number of turns, and (4) rigid structure maintaining mechanical and electrical stability. The hollow core (~300 µm diameter) allows the sensitive magnetic core to be loaded as a final step, minimizing contact that can damage magnetic domains.

3D-printed miniaturized single-axis fluxgate magnetometers in ceramic structures; large-scale, consistent manufacturing of science-grade sensors; addresses GSFC MSM production bottlenecks; precise and reproducible control of four key design features (wire thickness, turn spacing, turns, rigid structure).

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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