Preliminary design of a platinum wire temperature sensor for Martian atmosphere monitoring using additive manufacturing technologies

This work presents the development of a novel platinum wire Resistance Temperature Detector (RTD) designed for operation in the harsh Martian environment, within the “Space It Up” initiative. The current datasets of the Martian atmosphere measured parameters are limited in spatial and temporal coverage, highlighting the need for high-precision, robust sensors that can fill this gap. For this reason, accurate temperature measurements are essential to improve atmospheric models and support future human exploration missions and habitat design on Mars that require accurate thermal control. The proposed RTD uses a 700 mm length platinum wire of 60 μm diameter with a parylene insulation coating and a four-wire configuration. The preliminary designed sensor supporting structure has been produced using different Additive Manufacturing (AM) techniques, to enhance structural optimization through lightweight supports. Two prototypes have been developed and taken into consideration in this study: one in titanium via Direct Metal Laser Sintering (DMLS) and one in nanoceramic resin via Stereolithography (SLA). Due to the absence of geometric validation for the titanium specimen, the nanoceramic prototype demonstrated comparatively better structural geometry, as confirmed by FEM analyses and vibration testing. Also, to reduce production costs, AM techniques were selected after comparing different fabrication approaches. The sensor is suitable for integration into future rover, lander, and Entry-Descent-Landing (EDL) systems for Mars missions. As part of the characterization process, environmental qualification will be carried out through thermal- vacuum, calibration, and dust resistance tests.