3D Printing in Space and Materials Science

Field: Scientific research, space engineering, aviation, and materials science innovation
Technologies used: Selective Laser Sintering (SLS / 3D printing – Sintratec Kit, Sintratec PA12)

About the Project

The Hybrid Materials Laboratory at SUPSI University, led by Prof. Alberto Ortona, conducts research developing advanced composite materials capable of withstanding extreme temperatures and thermal shock. These materials are applied in spacecraft (e.g., in active thermal protection systems in the EU research project THOR), heat exchangers, catalysts, and filtration systems.

Engineering and Manufacturing Solutions

The long-used stereolithography (SLA) technology limited the production of complex porous structures and gyroids, so the institute transitioned to SLS printing:

Porous structure optimization: By varying sintering temperature, laser speed, and layer thickness, the laboratory investigated the mechanical strength of porous 3D lattice structures, aiming for minimum weight and maximum strength.
Sacrificial templates technology: 3D-printed polymer (Sintratec PA12) templates are coated with ceramic slurry. During thermal processing, the polymer burns away, leaving an extremely lightweight, hollow, and strong ceramic component.
High-performance prototypes: Samples withstand extremely high compression loads (e.g., a 40 mm cubic gyroid withstood up to 5 kN / 500 kg load).

Results Achieved

Expanded 3D printing boundaries: Opportunities have been opened to quickly and easily create complex geometry lattice and porous structures.
Industrial application: The ceramic coating technology refined in the laboratory and the printed structures are now manufactured industrially at the Swiss company EngiCer SA.
Innovation in aviation and space: The developed solutions contribute to the development of reusable spacecraft and next-generation hybrid ceramics.

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Problem

When developing materials resistant to high temperatures and thermal shock for space and aviation applications, the previously used stereolithography (SLA) technology limited the ability to produce complex porous and gyroid structures. Traditional methods did not allow easy creation of geometries that achieve the optimal ratio of minimum weight to maximum mechanical strength.

Solution

To optimize resources, SLS 3D printing with Sintratec PA12 material was selected, applying a technology based on the sacrificial template method. Printed porous 3D lattice structures are coated with ceramic slurry; during subsequent thermal processing, the polymer framework burns away, leaving an extremely lightweight, hollow, and durable ceramic component.

Result

Opportunities have been opened to quickly and easily create complex geometry lattice and porous structures. The printed structures can withstand high compression loads (e.g., a 40 mm cubic gyroid withstood up to 5 kN / 500 kg load). The process refined in the laboratory has been transferred to industrial production at the Swiss company EngiCer SA, and the resulting solutions have been applied in space research (e.g., in the EU project THOR).