A component instead of an assembly
Cooling channels, fins, and connections are formed as a single piece. This eliminates most soldered and welded joints, thereby reducing assembly and testing efforts.
Titanium Satellite Radiator Produced Using Metal 3D Printing
A lightweight heat exchanger made of Ti-6Al-4V (Grade 23) for temperature control in satellites and space systems.
When heat must be dissipated in a vacuum
Electronics, batteries, and instruments on board a satellite generate heat that cannot be dissipated into the surrounding air in a vacuum. Thermal control systems therefore transport this heat via a cooling medium to heat exchangers and radiators. This ensures that the components remain within their permissible temperature range.
Every additional gram increases launch costs. Conventionally manufactured heat exchangers often consist of many brazed or welded individual parts, and each joint requires assembly and testing effort and is prone to leaks. Fine channels and thin fins can hardly be produced economically through machining.
This is where a radiator produced via metal 3D printing can help.
The solution: a one-piece titanium radiator produced using metal 3D printing
The radiator is built layer by layer from Ti-6Al-4V Grade 23. Cooling channels, thin-walled fins, and fluid connections are formed as a single piece, eliminating most joints. The geometry can be directly tailored to the installation space, thermal load, and interfaces within the satellite.
Grade 23 is the ELI (“Extra Low Interstitial”) variant of Ti-6Al-4V. It has high strength combined with low density, good fracture toughness, and minimal thermal expansion. However, titanium is a poor heat conductor. This is compensated for by thin walls and a large surface area, and the layer thickness of 40 µm is well-suited for these fine structures.
After printing, the radiator undergoes stress-relief annealing. This relieves residual stresses from the printing process to prevent the component from warping. During the subsequent sandblasting, the surface is made uniform, and any adhering powder is removed.
Manufacturing Overview
The radiator was 3D-printed from Ti-6Al-4V (Grade 23), stress-relieved, and sandblasted.
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Manufacturing Data Material Layer Thickness Printing time Industry |
Post-processing
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Price of the manufacturing example shown: 970 €.
The price for a new project depends, among other factors, on the part geometry, material, quantity, and desired post-processing.
What the 3D-Printed Radiator Makes Possible
Large surface area for heat exchange
Thin-walled multichannel structures and fine lamellae compensate for titanium's low thermal conductivity. Such geometries are virtually impossible to manufacture using conventional methods.
Material only where it's needed
The geometry is designed to accommodate the installation space, thermal load, and interfaces within the satellite. This keeps the mass low, and different design variants can be tested without incurring tooling costs.
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Onur Yildirim
Head of Sales, Additive Manufacturing
Fislisbach, Switzerland