3d Printed Pipe Segments With Built-in Heating and Temperature Sensing Capabilities

Spacecraft thermal regulation ensures survival, optimal performance, and longevity by preventing overheating or freezing of onboard systems and components. Precise thermal management requires strategically placed sensors and heating elements for effective temperature control. These components monitor and adjust temperature variations, maintaining stable onboard conditions. However, current integration methods introduce constraints that hinder efficiency. In the framework of the EU project AHEAD, a pipe segment including 3D printed heating and temperature sensing elements was co-developed by CSEM (design, Aerosol Jet Printing sensor), LISI Aerospace Additive Manufacturing (metallic additive manufacturing) and Thales Alenia Space France (end-user requirement specifications, co-design, and validation testing). Thanks to built-in electrical wires, connector, heater, sensor and precisely machined terminations, this pipe segment is a one-part plug and play device. It offers heating power up to 60 W and temperature measurement from -65 to +85°C without the need for integrating external elements. This paper presents the results and lessons learned from the design (chapter 3), manufacturing (chapter 4) and testing of the prototypes (chapter 5). Tests include CT scanning, heater and sensor functional & performance tests (section 5.1), proof pressure and leak tests (section 5.2), vibrations tests (section 5.3), cleanliness tests (section 5.4), thermoelastic tests (section 5.5), thermal lifetime and performance tests (sections 5.6 and 5.7), sensor accuracy tests (section 5.8) and burst tests (section 5.9).