Additive Manufacturing of Copper Components for the Space Sector: A Technology Comparison

Additive manufacturing (AM) has been pointed out to be a pivotal enabling technology within the space sector, as it allows rethinking traditional approaches to space system design and manufacturing. Leveraging AM techniques holds immense promise for enhancing the performance and reliability of space systems, as demonstrated by the achievement of flight-proven status by a constantly increasing number of additively manufactured components. In addition, AM methods provide space companies with a new capacity to reduce production costs and lead time, to enhance the sustainability of the production chain, opening also new opportunities for in-space manufacturing. In this framework, AM of copper and its alloys has attracted a wide scientific and industrial interest in the space community. Indeed, it opens a variety of relevant applications, from high-performance propulsion systems to advanced thermal management solutions, from radio-frequency equipment to on-board electronics and new payload designs. Different AM processes are suitable to produce copper parts. Each of them is characterized by specific pros and cons and by inherent limitations. Understanding the actual application boundaries for each technology is crucial for an effective adoption of AM methods in the space sectors. This paper presents a technological comparison among different AM processes, namely powder bed fusion and material extrusion. The capabilities and the limits of such processes are compared using a reference geometry representative of geometrical shapes of interest for space system applications. Process-dependent defectiveness is investigated and characterized, highlighting the benefits and disadvantages of each method. Application scenarios, limitations and opportunities including also cost-benefit aspects are addressed and discussed to help stakeholders make informed decisions regarding the selection and adoption of AM processes for space system applications.