Launching hardware into orbit has always been expensive, but the economics of modern spaceflight are making lightweight engineering more important than ever. With launch costs approaching $7,000 per kilogram on rideshare missions, every gram matters. That reality has pushed aerospace engineers toward industrial additive manufacturing, where high-performance thermoplastics are helping redefine how CubeSat components are built.
Why Weight Matters in CubeSat Design
CubeSats are compact spacecraft built around standardized dimensions. A single unit measures roughly four inches on each side, and multiple units can be stacked together. Even larger 3U systems typically weigh only three to five kilograms.
Inside that small volume, every component must perform multiple functions. Structural elements often serve simultaneously as mounting features, thermal pathways, and cable management systems. These complex geometries are difficult and expensive to machine, making them ideal candidates for additive manufacturing.
As launch prices continue rising, reducing mass is no longer just an engineering objective. It has become a financial consideration. Every gram saved creates opportunities for additional sensors, larger batteries, or deployable antennas without exceeding strict mass budgets.
Why Standard Plastics Cannot Survive Space
Not all polymers belong in orbit. Common desktop materials such as PLA fail to meet the stringent requirements of aerospace applications.
One of the biggest challenges is outgassing. In the vacuum of space, certain plastics release volatile compounds that can contaminate optical systems and solar panels. To address this, NASA relies on ASTM E595 testing standards that establish limits on allowable outgassing.
Most materials fail these requirements. ULTEM®, however, has established itself as one of the few engineering polymers trusted throughout the aerospace industry.
ULTEM 9085 vs ULTEM 1010: Which Material Is Better?
ULTEM is the trade name for polyetherimide (PEI), a high-performance thermoplastic manufactured by SABIC. It offers exceptional thermal stability, low outgassing characteristics, and outstanding flame resistance.
ULTEM 9085
- Widely used in aerospace applications
- UL 94 V0 flame rating
- Excellent flame, smoke, and toxicity performance
- Trusted in aircraft interiors
ULTEM 1010
- Higher tensile strength
- Improved heat resistance
- Superior chemical resistance
- Outstanding mechanical properties
- UL 94 V0 flame rating
ULTEM 1010 sits at the top tier of engineering thermoplastics, but printing it successfully requires extremely high temperatures and strong bed adhesion.
How Industrial FDM Makes High-Performance Materials Practical
Printing advanced polymers such as ULTEM, PEEK, and PPSU presents challenges that go far beyond conventional materials. High chamber temperatures, elevated nozzle temperatures, and reliable build surface adhesion are essential.
As industrial FDM technology has matured, these materials have become increasingly accessible. Specialized adhesives and heated build environments have made repeatable production possible, enabling manufacturers to print parts that once required expensive machining processes.
Pumpkin Space Systems Demonstrates Real-World Space Applications
Pumpkin Space Systems has been supplying CubeSat hardware since 2003 and has delivered more than 150 CubeSat kits. NASA recognizes the company as a major provider of CubeSat structures.
One of its products, the BM2 intelligent lithium battery module, stores up to 100 watt-hours and delivers as much as 160 watts of power.
Originally, the frame surrounding the battery pack was CNC machined from solid ULTEM stock. While accurate, the process involved high costs and lengthy lead times.
Switching to 3D printed ULTEM 1010 provided several advantages:
- Reduced manufacturing lead times
- Lower production costs
- Improved design flexibility
- Equivalent material properties
- Enhanced heat and chemical resistance
- Excellent flame retardancy
What previously required weeks of machining could now be produced and tested within days.
FDM vs SLS for Space Applications
Many famous examples of 3D printed satellites rely on selective laser sintering (SLS), a powder-based technology that differs significantly from fused deposition modeling (FDM).
Projects such as KySat-2, ORS Sat-0, and NASA Langley’s GPX-2 employed SLS systems and specialized materials like Windform.
While SLS offers impressive capabilities, industrial FDM provides a more accessible path for organizations seeking in-house manufacturing.
Nylon SLS systems have become increasingly attainable, but high-temperature SLS platforms capable of processing materials such as ULTEM and PEEK remain considerably more expensive and complex.
NASA and Aerospace Companies Have Already Proven Printed ULTEM in Space
3D printed ULTEM components are far from experimental.
NASA’s Jet Propulsion Laboratory collaborated with Stratasys to produce ULTEM 9085 antenna arrays for the COSMIC-2 mission. These components achieved Technology Readiness Level 6 and ultimately flew aboard spacecraft launched in 2019.
Meanwhile, Spanish aerospace company Elecnor Deimos developed a fully FDM-manufactured 8U CubeSat structure and subjected it to rigorous vibration testing.
The technology has accumulated genuine flight heritage, proving that properly engineered polymer components can survive the demands of space.
Where Industrial FDM Delivers the Greatest Benefits
Fully 3D printed satellites are unlikely to replace metal structures entirely. Aluminum and titanium still play critical roles.
However, additive manufacturing excels in applications such as:
- Battery housings
- Antenna mounts
- Structural brackets
- Optical bench supports
- Thermal standoffs
- Deployable mechanisms
- Cable routing features
These are precisely the areas where design freedom and weight reduction create meaningful performance improvements.
The Future of Aerospace Manufacturing Is Hybrid
NASA’s 2024 Small Spacecraft State of the Art report included a dedicated section on polymer additive manufacturing, signaling the growing maturity of the technology.
The future is not about replacing traditional materials entirely. Instead, it involves combining metals and high-performance polymers where each delivers the greatest advantage.
As launch costs continue to rise and mission requirements become increasingly demanding, industrial FDM printing with materials like ULTEM 1010 is emerging as a practical solution for engineers seeking lighter, faster, and more efficient spacecraft designs.
In many cases, the math is simple. When every kilogram costs thousands of dollars to launch, high-performance printed polymers can offer a compelling advantage.