Multi-functional 3D printed and embedded sensors for satellite qualification structures

Three dimensional (3D) printing has recently gained attention in a variety of industries ranging from aerospace to biomedical. However, in order to create truly functional 3D printed structures, electronic functionality must be integrated into building sequence. This work explores the integration of both printed sensors (copper capacitive touch sensors) and embedded COTS sensors (surface mount accelerometers) in order to fabricate a space-flight qualification test coupon in the shape of a 1U CubeSat (10 × 10 × 10 cm) as required for stress testing. The 3D printed electronics were fabricated by an enhanced Multi3D 3D Printing system, allowing the direct integration of 3D printed dielectric structures with electronics components fabricated together using a single non-assembly build sequence. Both sensors and structures successfully demonstrated electronic functionality after full encapsulation, and show promise for integration in space based cube satellites.