3D Printing in Aerospace Industry

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How Windform is streamlining aerospace manufacturing

Overview

With the advancement of a dedicated range of 12 flight-ready composites for SLS 3D printing, Windform has emerged as a game-changer in streamlining the production of High-stress components of space vessels, satellites, launchers and other spacecraft components.

Lightness and performance that change the game

Up to 60 % weight reduction without compromising strength and thermal stability.

Boasting the lowest weight-to-density ratio in the industry, Windform composites allow aerospace engineers to create complex, integrated components with unrivaled lightness, accuracy, and durability.

Field-tested in space and on Earth

Operational both in orbit and for ground applications, systems and components 3D printed in Windform have survived many adverse conditions and are enhancing the efficiency of satellites, launchers, as well as propellerhead systems subject to extreme high and low temperatures.

Dedicated to selective laser sintering technology, and reinforced with carbon and glass fiber, space components boost from maximum lightness matched to resistance to the harshest operating conditions in space, including 14G vibrations, shocks, water ingress, exposure to harsh chemicals, and extreme low and high temperatures.

The Challenge

Realizing reliable Hybrid Rocket Propulsion System

Conventional hybrid rocket propulsion systems face the hurdle of incorporating multiple components into a single functional unit, often sacrificing durability or efficiency. In addition, the intricate 2-chamber design typically hinders production speed.

Our Solution

Harnessing the power of 3D printing technology with Windform XT2.0 , we have revolutionized hybrid rocket propulsion by integrating all components into a monolithic, robust structure. This single-piece design boasts unparalleled tensile strength, seamlessly withstands extreme launch conditions, and eliminates the weaknesses of other 3D printing materials.

Streamlining the intricate 2-chamber design into a solid all-in-one structure that defies the limitations experienced with other 3D printing materials and expedites production of functional components.

The monolithic structure of Windform XT2.0 boosts tensile strength and withstands high pressure with unwavering resilience. Its compactness and energy density enable multiple restarts and peak-level testing without compromising performanceS.

Unique Advantages

Unparalleled Pressure Resistance

ranging from 1 to 137.9 bar

Outgassing proof

Retains its integrity and prevents the release of harmful gasses, maintaining safety protocols.

Tested to Peak Performance

Proven to deliver a peak thrust of 27.6N for continuous 16-second operation

Extreme Temperature Tolerance

From +2204°C to -40°C, ensuring resilience in diverse environments.

Resilient to Water and Liquids

Withstands entrance of water and other liquids without compromising its structural integrity

Easy aerospace compliance

Given the strict certifications and demanding safety approvals the aerospace and aviation sector must address, you can rely on pre qualified components thanks to the Windform space ready materials and to our EN9100 certification covering manufacturing processes and management systems for the highest levels of effectiveness in production and post-production processes.

We support our customers in the additive production of aerospace vehicles, related systems, components, and equipment, with dedicated technological know-how and expertise.

Both EN 9100:2018 and ISO 9001 certifications are held by the production system of CRP Technology’s Windform composite material for SLS and related systems

Should you need any additional compliance or certification, like Outgassing, please refer to specific material conformity to technical criteria and data from technical and quality data section.

High-Grade SLS 3D Printing
materials for Aerospace

Windform GT, SP, XT 2.0 are compliant to Outgassing proof according to NASA requirements.
Windform LX 3.0, RS, XT 2.0 are compliant to Outgassing proof according to ESA requirements.

The choice of main Aerospace Agencies

Over a dozen material variants designed to withstand the extremely harsh environments of aerospace and defense applications. Aerospace engineers have access to a wide variety of heavy-duty materials that can withstand microgravity, propulsion systems, 14G vibrations, and aerospace launches.

Windform’s range embeds exclusive features and benefits to construct reliable and highly efficient space systems.

High Low Temperature Resistance

Full range operating temperatures from +191,9° C[*] to -40° C

Resistance to Vibrations, Corrosion, Water and Chemical Agents

The non-metal nature of Windform composites, reinforced with carbon or glass fiber as well as the TPU polymers ensure resistance to water and liquid absorption, as well as chemical agents and corrosion for years of operation without issues.

Fire Retardancy

According to the UL94 or FAR rules they can be employed to minimize fire risks.

Aerodynamic finish

The attainment of optimal precision and aerodynamic capabilities is facilitated by our extensive finishing expertise and superior material quality.

Highest insulation for fitting electronics

High Density Electronics Integration in extremely narrow spaces (including Antenna systems, cameras, transmission systems, and various electronic components), integration of specific battery compartments, pouches, and cases.

Top Mechanical resistance including 14G vibrations

A combination of high tensile strength and modulus, high stiffness matched to flexibility and the resistance to shocks are matched to extra low density to weight ratio for unrivaled lightness.

Outgassing Proof

According to NASA and ESA

Complex/thin sections realization

[*] Referring to the Heat Deflection Temperature

Test the potential of Windform Additive Manufacturing to enhance your products development, life-cycle and supply chain.