Launching large, rigid satellite dishes into orbit is an expensive and energy-hungry task. But what if those massive structures could start out flat—and then unfold or “grow” into their curved shapes once they’re in space?
That futuristic idea is now closer to reality, thanks to researchers at the University of Illinois Urbana-Champaign.
A team led by aerospace Ph.D. student Ivan Wu and his advisor Jeff Baur has developed a low-energy, scalable technique that can morph 2D materials into strong 3D structures using a combination of 3D printing and frontal polymerization—a heat-triggered chemical process.
The innovation could revolutionize how satellites, antennas, and other space structures are made. Instead of launching bulky components that take up valuable cargo space, engineers could send lightweight, flat parts that curve into shape once activated.
Wu said earlier that low-energy approaches couldn’t create stiff enough structures for aerospace use. “In this case, our collaborators in the Beckman Institute developed a recipe for a pure resin system that’s very energy efficient,” he said.
“And we have a 3D printer that can print commercial aerospace-grade composite structures. I think the breakthrough was combining those two things into one.”
Printing shapes from code
The team used a continuous carbon fiber 3D printer that laid down hair-thin bundles of fiber. As the printer drew the bundles onto a flat bed, each layer was partially cured with ultraviolet light.
The structure was then frozen with liquid resin and later activated with heat—requiring no large autoclaves or ovens.
The trick lies in frontal polymerization, a process that turns the flat sheet into a curved form through a self-propagating reaction.
Wu explained that the small heat pulse works like a spark: “Much like a single match can set a sheet of paper or a house on fire, the thermal trigger is the same amount of energy for any size structure.” That scalability makes the process ideal for large aerospace parts like satellite dishes.
The researchers used mathematical equations to solve what Wu calls “the inverse problem.”
“You have a design for the 3D shape you want, but what is the 2D pattern to print that results in that shape?” he said.
Wu coded the printing patterns to create five configurations: a spiral cylinder, a twisted strip, a cone, a saddle, and a parabolic dish—the most practical design for satellite applications.
Inspired by kirigami art
Wu found inspiration in kirigami, a Japanese art similar to origami but involving both folds and cuts.
“I see research as very artistic. Sometimes, you get a creative idea and just pursue it,” he said. The parabolic dish began as a flat sheet with petal-like cuts that curved toward a center point, forming the smooth surface needed for satellite signals.
The team achieved higher stiffness and lower energy use than previous work, but Wu said the structures still need reinforcement for space use. “We suggest using the activated 3D shapes as molds to manufacture high-stiffness structures in space,” he explained.
Beyond satellites, Wu said the same process could help build infrastructure in remote areas on Earth.
The research, supported by the Air Force Research Laboratory, opens a path toward self-forming aerospace systems and efficient space manufacturing.