Additive Manufacturing of Structural Components for PocketQube-Class Satellites: A Systematic Review of Materials, Processes, Qualification Pathways, and ECSS Compliance

PocketQube-class satellites have emerged as a cost-effective platform for space access; however, their extreme mass, volume, and dimensional constraints challenge conventional manufacturing approaches. This systematic review examines the state of the art of additive manufacturing (AM) for PocketQube structural systems between 2015 and 2026, focusing on materials, manufacturing processes, design methodologies, qualification frameworks, and flight heritage. A PRISMA-guided review methodology combined with a PICO/SPIDER-based selection framework was applied to analyse the peer-reviewed literature, technical standards, and documented mission data. The results indicate that AM has evolved from a prototyping tool into a viable production technology for picosatellite structures, enabling mass reductions of 30–60%, increased geometric complexity, functional integration, and improved packaging efficiency within the 50 × 50 × 50 mm PocketQube envelope. Polymer-based selective laser sintering, particularly Windform XT 2.0, currently represents the highest-maturity solution, while laser powder bed fusion of AlSi10Mg and Scalmalloy® shows significant potential for future primary structures. The review further identifies a persistent gap between technological maturity and qualification readiness, as existing ECSS, NASA, and ISO/ASTM standards remain insufficiently tailored to PocketQube-class hardware. Future research should prioritise dedicated qualification pathways, in-orbit validation of metallic AM structures, and multifunctional topology-optimised architectures to enable the next generation of ultra-small spacecraft.