Fraunhofer IAP has developed a new generation of ultralight space components based on shape-memory polymers, aiming to reduce both mass and mechanical complexity in satellite and spacecraft deployment systems.
The work has been carried out within the AM-SPACE project, which combines functional polymer materials with additive manufacturing to produce components capable of changing shape in response to thermal activation.
Among the demonstrators is a hinge designed for deploying solar panels or antennas weighing around 1.4 grams, representing a 93% weight reduction compared with a conventional metal solution.
The concept relies on the ability of shape-memory polymers to be programmed into a temporary configuration and return to their original geometry when heated above a defined transition temperature. This allows the material to provide both structural and actuation functions, reducing the number of mechanical parts required.
For space applications, the benefit is significant: every gram saved can help lower launch costs, while simpler mechanisms can reduce the number of components exposed to wear or failure.
Additive manufacturing also enables customised geometries and integrated components without complex tooling, supporting faster production of small batches and mission-specific parts.
Fraunhofer IAP is targeting operational applications in deployment systems for solar arrays, antennas and other satellite structures, where low mass, reliability and compact stowage are critical requirements.
The technology will also be presented at Formnext and Space Tech Expo Europe, highlighting the potential of smart materials and 3D printing for a new generation of multifunctional space.
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11 November 2026
