Discover how advanced 3D printing is revolutionizing satellite battery packs and high-performance thermoplastics like ULTEM 1010 for space applications.
From Prototype to Orbit: ULTEM 1010 in Production
One of the standout applications in aerospace additive manufacturing today is a 3D printed part used in a battery pack housing for satellites. The final production part, manufactured using ULTEM 1010, is a high-temperature amorphous thermoplastic known for its UL94 V-0 FST rating. This means it’s flame-retardant, self-extinguishing, and emits low smoke — key traits for aerospace and defense systems.
This component was originally CNC machined from ULTEM blocks, a costly and time-consuming approach. To improve customization and reduce overhead, the manufacturer transitioned to 3D printing for rapid prototyping and production. The geometry was verified for printability, and the results were successful, leading to faster iteration cycles and significantly lower production costs.
Meet the BM2 Battery Module
The part in question is part of the BM2 Intelligent Protected Lithium Battery Module. This modular power system uses eight high-current 18650 lithium-ion cells, delivering up to 160W of power and storing up to 100Wh of energy. Designed for nanosatellite platforms like Pumpkin Space’s Supernova structures, it features:
- Fast charging (minimum 5A)
- Compatibility with 1U to 3U CubeSat structures
- Advanced SOC (State of Charge) monitoring
- Vibration-optimized and thermally-managed enclosures
With a price tag of around $10,000, these battery modules are high-end, mission-critical systems — and a perfect candidate for the precision and flexibility of high-temp 3D printing.
Material Deep Dive: The Stars of Aerospace 3D Printing
Let’s break down the thermoplastics that are reshaping space part manufacturing:
- ULTEM 1010 – The gold standard for high-temp, chemically resistant parts. Its aesthetic and structural properties make it ideal for aerospace components.
- ULTEM 9085 – A slightly lower-temp alternative that prints beautifully and offers robust strength with easier flow.
- PPSU & PSU – Polyphenylsulfone and polysulfone, both known for heat and chemical resistance. PPSU is preferred for aerospace-grade durability.
- PVDF – A fluorinated polymer nearly immune to solvents and chemicals, though notoriously difficult to print due to poor adhesion properties.
- CF-Nylons & HTN (High Temp Nylon) – These carbon fiber-infused filaments offer strength and heat resistance, especially PPA-based nylons which are engineered for aerospace-grade performance.
- CF-PEEK & CF-ULTEM – Carbon fiber-reinforced versions of already high-performing materials, increasing rigidity and thermal stability — albeit at the cost of increased brittleness.
Why Adhesion Matters: NanoPolymer to the Rescue
Bed adhesion is the Achilles’ heel of high-temp additive manufacturing. Even miracle materials like PVDF and PEEK can warp or delaminate. That’s where nano-polymer adhesive come into play — designed to bond nearly every thermoplastic (except polypropylene) reliably. This makes it possible to achieve strong layer adhesion and minimize warping, even with the most stubborn materials.
Rapid Manufacturing with Real-World Results
The key takeaway? Additive manufacturing is no longer limited to prototypes. It’s now fully integrated into functional, end-use aerospace components. From custom battery pack enclosures to structural CubeSat parts, engineers are leveraging 3D printing to reduce lead times, increase flexibility, and cut costs.
Whether you’re building nanosatellites or under-the-hood automotive systems, high-temp thermoplastics like ULTEM, PPSU, and CF-Nylon are unlocking new design possibilities.
Get Started with Advanced Materials
Looking to explore these materials yourself? Whether it’s FDM, SLS, SLA, or even 3D scanning and design services — you’ll find a full range of solutions at Vision Miner.
Don’t just prototype — produce. From material selection to part optimization, the future of aerospace 3D printing is here.
Interested in more? Explore high-performance 3D printing materials, software, and equipment at visionminer.com/materials.