Case Study: Lockheed Martin Space Systems achieves repeatable, flight‑ready ESD 3D‑printed parts for Orion with Stratasys

Deep Space with Humans on Board New Material Enables 3D Printed Parts on Orion

Lockheed Martin Space Systems faced the challenge of producing repeatable, flight‑worthy polymer components for NASA’s Orion deep‑space missions that meet strict thermal, outgassing and electrostatic‑dissipative (ESD) requirements while reducing cost and schedule across multiple capsules. To close gaps in materials and scale additive manufacturing, Lockheed Martin partnered with Stratasys, deploying Stratasys printers (including the Fortus 900mc) and beta testing the new Antero (ESD) PEKK material.

Stratasys supplied the Fortus 900mc platform and Antero (ESD) PEKK, enabling Lockheed Martin Space Systems to 3D print production parts—most notably a one‑meter, six‑piece ESD PEKK docking hatch cover for Orion—while eliminating coatings and much post‑processing. The Stratasys solution delivered consistent, repeatable builds that moved components from prototyping into production, produced “orders of magnitude” savings in cost and schedule, and supports more than 100 3D‑printed parts on EM‑1 with additional Antero (ESD) parts planned for future flights.

Lockheed Martin Space Systems

Brian Kaplun

Manager, Additive Manufacturing