Plasma Jet Printing Technology (Various Configurations)

Space Foundry’s patented plasma jet printing process enables direct-write manufacturing of conductive and dielectric materials without pre- or post-treatment. The technology aerosolizes metal-ion inks, introduces them into a reactive plasma environment, performs in-situ reduction, and deposits conductive material directly onto the target surface in dry form. This allows for printing on curved, vertical, and complex 3D surfaces, supporting multiple orientations and reliable adhesion across various substrates. The process supports copper, silver, and dielectric printing workflows for applications such as antennas, sensors, and RF structures. It replaces multi-step print, cure, align, and repeat cycles with a simpler direct-write approach.

The platform is designed for use cases where conventional additive methods struggle with curved surfaces, adhesion, orientation, thickness building, or process complexity. Applications include conformal antennas, frequency selective surfaces, electromagnetic shielding, and RF structures for aircraft, UAVs, missiles, and related platforms. It also supports electronics integrated into curved vehicle surfaces like LiDAR heaters and sensor structures. A key emerging use case is in-space manufacturing (ISM) of electronic components for both space and terrestrial applications, with plans to enable in-space metallization for a broad range of applications. Other uses include printed sensors, EMI shielding, and communication features for robotic platforms, and a future pathway for conformal electronics in sensors, monitoring devices, implants, and wearable systems.

Space Foundry offers multiple hardware configurations, including desktop development systems for R&D and process development, conformal printers for non-planar surfaces, continuous printing configurations for flexible substrates, robotic integrations for complex geometries, and industrial-scale systems for large structures. They also provide custom process/product development and printed services, allowing customers to leverage their technology without capital equipment expenditure.