3D aerospace manufacturing start-up NESST Srl has designed, additively manufactured, and validated a CubeSat 3U structure as part of an Italian Space Agency (ISA) and European Space Agency (ESA)-funded project.
NESST Srl deployed the ROBOZE ARGO 500 platform and Carbon PEEK to manufacture the structural components, with rigorous testing and material characterisation demonstrating that Fused Filament Fabrication (FFF) delivers mechanical performance comparable to that of conventional aluminium alloys. The material has also met the strict outgassing requirements defined by the ECSS-Q-ST-70-02C standard.
By transitioning from conventional subtractive manufacturing to advanced 3D printing, ROBOZE says NESST Srl has 'unlocked the potential for extreme geometrical customisation.' ROBOZE has so far supported NESST Srl with the definition of optimal 3D printing parameters during the testing phase, ensuring the material met stringent space industry standards.
"Proving that FFF-processed polymers can rival traditional aluminium alloys marks a significant shift in how we conceive satellite manufacturing. This project validates our core vision: additive manufacturing is a strategic enabler for extreme structural customisation and cost-efficiency. We are already focusing on Phase 2 of the project, where we will leverage this design freedom to increasingly functionalise the CubeSat structures, directly integrating elements such as harnesses, electronics, [and] microfluidics," said Francesco Lucia, Technical Manager at NESST Srl.
"We are proud to have provided our technical support and manufacturing technology to NESST Srl for this milestone. Optimising the FFF process for high-performance polymers is exactly what our technology is built for, and this project highlights the readiness of these materials for the evolving space economy," added Alessio Lorusso, Founder and CEO of Roboze.
Last month, Airbus qualified the ROBOZE ARGO 500 HYPERSPEED 3D printing platform for secondary structural parts, with the ULTEM 9085 material meeting Airbus' requirements for mechanical performance, flame retardancy, repeatability, process control, and traceability.
