JPL 3D-Printed Part Springs Forward

With a simple motion, a jack-in-the-box-like spring designed at NASA’s Jet Propulsion Laboratory showed the potential of additive manufacturing, also known as 3D printing, to cut costs and complexity for futuristic space antennas. Called JPL Additive Compliant Canister (JACC), the spring deployed on a small commercial spacecraft, Proteus Space’s Mercury One, on Feb. 3, 2026. An onboard camera captured this still image of JACC after deployment as the spacecraft passed over Antarctica in low Earth orbit.

Figure A is a video of the spring popping out of its container while the spacecraft was over the Pacific Ocean.

JACC is one of two JPL payloads on the spacecraft that are demonstrating new technologies designed to take up reduced volume while precisely deploying antennas on future orbiters. JACC’s success demonstrates that 3D-printed mechanisms can be built faster, cheaper, and with less complexity than traditionally fabricated space hardware.

Printed out of titanium, JACC uses three times fewer parts than similar structures: Combined into a single part is a hinge, panel, compression spring, and two torsion springs. Weighing just over 1 pound (498 grams), it is about 4 inches (10 centimeters) on each side. The spring, which extends from a packed height of just over 1 inch to about 6 inches (3 centimeters to 15 centimeters), is modeled after communication antennas commonly used on satellites.

The second demonstration payload aboard Mercury One is the Solid Underconstrained Multi-Frequency (SUM) Deployable Antenna for Earth Science. Together with JACC, the two payloads go by the name Prototype Actuated Nonlinear Deployables Offering Repeatable Accuracy Stowed on a Box (PANDORASBox). They were both conceived, built, tested, and delivered for flight by JPL in less than one year on minimal budgets.

Mercury One launched from Vandenberg Space Force Base in California on Nov. 28, 2025, as part of SpaceX’s Transporter-15 mission.

JPL internal research development funds supported JACC, as did NASA’s Earth Science Technology Office (ESTO).