NASA Successfully Tests 3D Printed Spring Mechanism in Low Earth Orbit

A New Era for Space Hardware

In a milestone for aerospace additive manufacturing, NASA's Jet Propulsion Laboratory (JPL) has successfully tested a 3D printed deployment mechanism in low Earth orbit. The device, called the JPL Additive Compliant Canister (JACC), activated aboard Proteus Space's Mercury One satellite on February 3, 2026, marking a significant proof-of-concept for 3D printed space components.

What JACC Does

The JACC mechanism demonstrates how a single 3D printed titanium component can replace multiple traditionally manufactured parts. The device consolidates a hinge, panel, compression spring, and two torsion springs into one unified piece—using three times fewer parts than conventional assemblies.

Measuring approximately 4 inches (10 cm) per side and weighing just over 1 pound (498 grams), the mechanism extends from a compressed height of just over 1 inch to roughly 6 inches. It was designed based on principles used in standard satellite communication antennas.

Why This Matters

Traditional satellite hardware requires extensive machining, assembly, and testing—processes that drive up both cost and development time. By 3D printing the JACC, JPL was able to consolidate multiple mechanical elements into a single component that would otherwise require numerous parts and complex assembly.

The demonstration proves that additive manufacturing can produce flight-ready hardware capable of surviving the harsh environment of space while reducing both expense and design complexity. This aligns with a broader industry trend where aerospace companies are increasingly turning to 3D printing for antenna systems, radiation shields, and other critical components.

The Bigger Picture

NASA isn't alone in pushing 3D printing for space applications. Australian firm Fleet Space partnered with 3D Systems to produce 55 RF patch antennas per run within just three weeks for their Alpha satellite constellation. Meanwhile, Orbital Composites secured a $1.7 million U.S. Space Force contract to advance in-space antenna manufacturing.

The JACC was funded by JPL's internal research development resources and NASA's Earth Science Technology Office (ESTO). Both JACC and a companion payload—the Solid Underconstrained Multi-Frequency (SUM) Deployable Antenna—were developed, tested, and prepared for launch within just twelve months.

The Mercury One spacecraft launched from Vandenberg Space Force Base on November 28, 2025, aboard SpaceX's Transporter-15 flight.