Research Projects

This work focuses on addressing challenges in space hardware by integrating 3D printing with advanced manufacturing methods. These methods improve surface integrity, which is crucial for space-grade components like feed horns, waveguides, and antenna reflectors made from Carbon Fiber-Reinforced Plastic (CFRP). CFRP is known for being lightweight and high strength-to-weight ratio, making it ideal for space applications. However, it has limitations in space environments where specific electrical, thermal, and environmental resistances are required. While CFRP works up to 10 GHz, it faces issues like uneven conductivity, sensitivity to environmental changes, and signal loss in complex shapes due to anisotropy. In space, extreme conditions such as high radiation, wide temperature fluctuations, and electromagnetic interference (EMI) pose additional challenges for materials. Space hardware must be able to withstand these stresses while maintaining functionality. One way to improve CFRP’s performance is through metallization. Metallizing CFRP enhances its electrical conductivity, EMI shielding, and thermal management, which are important for components exposed to high-frequency signals and harsh space conditions. Metallization also enables electronic parts to be soldered onto CFRP elements. The process of metallizing CFRP can involve techniques such as electroless plating and electroplating, which create conductive surfaces, making the material more suitable for use in space antennas and shielding applications. Researchers are exploring new ways to improve materials using advanced manufacturing techniques, with metallization being a key focus. A major challenge with using 3D-printed CFRP in space hardware is creating even metal coatings, especially around corners and edges. The rough surface of 3D-printed parts causes uneven current flow, which reduces performance, especially at high frequencies where current stays on the surface (skin effect). To fix this, the metal coating must be consistently thick, smooth, and conductive. The work aims to achieve this by applying electroless plating on CFRP components made using the fused deposition modelling (FDM) method. The goal is to uniformly increase the thickness of the metal coating using electroplating, followed by electropolishing to improve electrical and thermal conductivity. After completing the metallization and electropolishing process, the RF performance of the CFRP antennas will be tested to ensure they meet the required specifications. The major challenge is ensuring that the metallization can withstand the extreme conditions of space, including orbit environments. While 3D printing allows for complex designs, it often struggles to achieve the surface integrity needed for high-performance space applications. Therefore, optimizing the manufacturing process to improve CFRP’s suitability for space applications is a key focus of this research.