Rapid Prototyping of Satellite Shields: 3D Printed Carbon Fiber and Kevlar Composites for Hypervelocity Impact Protection

This study explores the potential of 3D-printed composite shields for protecting satellites against hypervelocity impacts from space debris. Using a novel approach that integrates carbon fiber and Kevlar filaments, the paper presents a cost-effective and time-efficient methodology development for rapid prototyping satellite protection systems. Ten test samples were designed and manufactured implementing a dual-filament 3D printing process, employing carbon fiber as the primary structural material and Kevlar as the core. These shields were tested under simulated orbital collision conditions using a two-stage light-gas gun. The experimental results demonstrate the shields' effectiveness against hypervelocity impacts, revealing a significant correlation between manufacturing parameters and impact resistance. Preliminary results suggest that this methodology enables the development of customized, efficient shielding solutions with reduced production times and costs. A follow-up experimental campaign is outlined to further refine the technology, optimize the associated uncertainty range and assess its broader applications in space systems. This research contributes to the growing field of space debris mitigation, offering a promising approach to enhancing the resilience of orbital assets against collision threats.