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

3d Printed Pipe Segments With Built-in Heating and Temperature Sensing Capabilities | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article 3d Printed Pipe Segments With Built-in Heating and Temperature Sensing Capabilities Lisa Salamin, Hervé Saudan, Lionel Kiener, Julien Rouvinet, David Novo, and 11 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7320194/v1 This work is licensed under a CC BY 4.0 License Status: Under Revision Version 1 posted 8 You are reading this latest preprint version Abstract 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). spacecraft thermal management mechanically pumped loop additive manufacturing embedded sensing multifunctional components design for additive manufacturing (DfAM) Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Revision Version 1 posted Editorial decision: Revision requested 26 Jan, 2026 Reviews received at journal 29 Nov, 2025 Reviewers agreed at journal 13 Nov, 2025 Reviewers agreed at journal 25 Aug, 2025 Reviewers invited by journal 21 Aug, 2025 Editor assigned by journal 10 Aug, 2025 Submission checks completed at journal 08 Aug, 2025 First submitted to journal 07 Aug, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7320194","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":580471130,"identity":"a0979a8f-383e-4945-a761-b3508f0d1c0e","order_by":0,"name":"Lisa 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