In-Space Manufacturing of Morphing Electronics

Shape memory polymers (SMPs) are smart materials capable of “remembering” and reverting to a pre-set shape upon exposure to specific stimuli like heat or light, even after substantial deformation. When combined with flexible electronics, SMPs enable innovative morphing structures for space applications. These structures, such as adaptive satellite antennas and solar arrays, possess the capability to reconfigure themselves dynamically, thereby optimizing signal reception, energy harvesting, and spacecraft aerodynamics in accordance with the unique demands of each mission. This research merges material extrusion (MEX) and fused filament deposition techniques to advance the additive manufacturing of SMP-based morphing structures, which feature conductive silver traces encased in a shape memory polylactic acid/thermoplastic matrix. Thermo-mechanical material properties of the printed SMP, including the maximum recoverable strain and glass transition temperature, were first characterized. Subsequently, a series of SMP-based structures were prototyped to demonstrate their morphing capabilities in response to light, thermal, or electrical stimuli. These results confirmed the feasibility of on-demand manufacturing of morphing structures, reducing the constraints of Earth-based pre-launch design limits and ensuring sustainability for future deep-space exploration missions.