3D Printing for Satellites? The ULTEM 1010 Part That Made It

In this episode, we’re diving into one of the most exciting real-world applications of ULTEM 1010 we’ve seen to date — a custom battery module housing for Pumpkin Space Systems, built for use in small satellites. This isn’t just a case study — it’s a deep dive into how high-performance 3D printing is actively being used to power commercial space technology.

Pumpkin Space, a leading player in the nanosatellite and CubeSat world, approached Vision Miner to explore 3D printing options for a battery housing they were previously machining from solid blocks of ULTEM. The result? A lightweight, functional, and highly customizable enclosure produced using ULTEM 1010 filament — capable of meeting the strict demands of aerospace environments.

ULTEM 1010 is a high-temperature amorphous thermoplastic known for its excellent mechanical properties, chemical resistance, and thermal stability. With an FST rating of UL94 V-0, it’s self-extinguishing, emits low smoke, and is ideal for confined, high-risk environments like space.

In this video, we walk through the original CNC part, the printed versions, and why additive manufacturing became the smarter choice. From reducing stock overhead and iteration time to enabling small-batch customization, the advantages of using FDM 3D printing for mission-critical aerospace components become crystal clear. We also discuss the actual material specs of ULTEM 1010, how it compares to other high-performance thermoplastics like PEKK, PEEK, and PPSU, and why it’s a favorite here at Vision Miner.

Whether you’re working in aerospace, automotive, defense, or electronics — if you’re dealing with tough environments that demand reliability, this is the kind of use-case that proves high-temp polymers are more than just hype.

We also touch on:

The role of 3D printing in CubeSat manufacturing
Pumpkin’s $10,000 modular battery pack and its specs
ULTEM 1010’s amorphous structure and thermal capabilities
Benefits of printing vs CNC in low-volume production
Use of CF ULTEM and how it compares acoustically and structurally to standard grades
Other materials explored during the project (PC, PVDF, PPSU, HTN, and more)

Plus — if you’re curious about printing exotic materials, we showcase several high-performance polymers and drop tips on adhesion, print settings, and real-world usability. We also talk shop on chopped carbon fiber blends and the myths surrounding “tough PLA” and fiber-filled filaments.

This isn’t just a showcase. It’s a masterclass in what’s possible with industrial-grade FDM printing.

If you’re developing mission-critical systems and want to take advantage of the speed, flexibility, and performance that additive manufacturing offers, reach out — we’ve worked with NASA, aerospace startups, EV companies, defense contractors, and beyond. We know what it takes to get parts made right the first time.

At Vision Miner, we specialize in Functional 3D printing, especially high-performance plastics like PEEK, ULTEM, PPSU, PPS, CFPA, and more.

We also have extensive experience with 3D scanners, and a whole array of solutions available for purchase.

If you’re interested in using functional 3D printing and materials in your business, feel free to reach out, and we can help you make the right choice for your application.

Call 833-774-6863 or email contact@visionminer.com, and we’re here to help!

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Chapters:
00:00 Introduction
00:36 Let's talk about the final part that's in production
01:10 The Original Part
03:24 So, what is this battery pack?
05:24 Rob, this one is in fact NOT PCTG
06:29 Bed Adhesion is Key
07:21 HTN
07:51 Something is coming soon in the summer
08:15 PSU
09:11 ULTEM 1010
09:55 ULTEM 9085
11:13 PPS
13:32 So what is EPA-CF?
14:42 CF ULTEM, CF-PEEK, CF-PP, CF-PC
14:52 CF-PP vs. CF-PC sound test
15:03 CF-PEEK vs. CF-ULTEM 1010 sound test
15:20 I guess we're sound testing everything now?
15:49 Reach out, we're here to help :)

Видео 3D Printing for Satellites? The ULTEM 1010 Part That Made It канала Vision Miner