Flat to flight: 3D-printed materials morph into satellite shapes

Researchers at the University of Illinois Urbana-Champaign have developed an innovative method to transform flat 3D-printed sheets into curved, strong satellite structures using a combination of 3D printing and frontal polymerization—a heat-triggered chemical reaction. This low-energy, scalable technique enables lightweight, flat components to be launched into space and then morph into complex 3D shapes such as satellite dishes, antennas, and other aerospace structures, potentially reducing launch costs and cargo space requirements. The process involves printing continuous carbon fiber composites partially cured with ultraviolet light, then activating the flat parts with a small heat pulse that triggers a self-propagating reaction to form the desired curved shapes. The team addressed the "inverse problem" of determining the 2D printing pattern needed to achieve specific 3D shapes, successfully creating configurations including a spiral cylinder, twisted strip, cone, saddle, and notably a parabolic dish ideal for satellite applications. Inspired by kirigami art, the parabolic dish design uses petal-like