NASA Advances Space Antenna Technology with 3D-Printed Titanium Spring

A groundbreaking 3D-printed titanium spring, developed by NASA’s Jet Propulsion Laboratory (JPL), has successfully deployed in space, demonstrating the potential of additive manufacturing to revolutionize the design and deployment of space antennas. The spring, part of the JPL Additive Compliant Canister (JACC) project, was launched aboard Proteus Space’s Mercury One spacecraft on February 3, 2026.

Reducing Complexity and Weight in Space

Traditional space antennas often require numerous individual parts for assembly, and deployment. JACC streamlines this process by integrating a hinge, panel, compression spring, and two torsion springs into a single, 3D-printed component. This innovative design reduces the part count by a factor of three, significantly decreasing both the weight and volume of the antenna. The entire package weighs just 498 grams (approximately 1 pound) and measures 10 cm (4 inches) on each side.

Deployment and Testing

The spring-like antenna was deployed on Proteus Space’s Mercury One spacecraft, a small commercial satellite and the first developed using AI [1]. An onboard camera captured footage of the spring extending from a packed height of 3 cm (1 inch) to 15 cm (6 inches) as the spacecraft passed over the Pacific Ocean in Low-Earth Orbit (LEO) [1]. The successful deployment validates the viability of 3D-printed mechanisms for space applications.

Mercury One and the SpaceX Transporter-15 Mission

Mercury One was launched aboard SpaceX’s Transporter-15 mission on November 28, 2025, from Vandenberg Space Force Base in California [3]. Proteus Space completed the design, AI&T, launch brokering, licensing, launch integration, LEOPs, and operations in-house, showcasing full lifecycle capabilities for rapid access to space [3]. The mission was executed under a SpaceWERX and AFRL Space Vehicles Directorate contract.

PANDORASBox: A Suite of Deployable Technologies

JACC is one of two technology demonstrators aboard Mercury One. The other is the Solid Underconstrained Multi-Frequency (SUM) Deployable Antenna for Earth Science. Together, these payloads are known as Prototype Actuated Nonlinear Deployables Offering Repeatable Accuracy Stowed on a Box (PANDORASBox) [4]. Both were developed by JPL in under a year with minimal funding.

Future Implications

The success of JACC demonstrates the potential of 3D printing to build space hardware faster, cheaper, and with less complexity than traditional manufacturing methods. This technology could be crucial for future missions, particularly those venturing far from Earth where resupply opportunities are limited [1]. NASA’s internal research development funds and the Earth Science Technology Office (ESTO) supported the development of JACC [4].