German company Horizon Microtechnologies is accelerating its path toward industrial manufacturing for its specialized additive manufacturing (3D printing) platform for metal-polymers. This move is driven by IP-MASS, a two-year industrial expansion project supported by 500,000 euros, and is further bolstered by the company's selection for the ESA Phi-Lab Austria program under the European Space Agency.
IP-MASS Project: From Prototypes to Mass Production
The new program aims to expand the company's capabilities in printing, coating, and process validation, specifically for manufacturing shielding housings and passive radio frequency (RF) components. The company is not merely producing experimental models; it aims to reach a production capacity of 50,000 precision-coated components, providing a repeatable manufacturing framework that meets the requirements of "Satellite Constellations," which demand large quantities rather than individual pieces.
How the Technology Works and Its Competitive Advantage
Horizon's technology relies on combining the precision of 3D polymer printing with conformal metallisation and protective coatings. The mechanism works as follows:
- Structure: The 3D printed polymer provides the base geometry with high precision.
- Function: Metal is applied only at the thickness required to perform the technical function.
This approach allows for the replacement of light metals, such as aluminum, with metal-polymer composites, contributing to a weight reduction of up to 40%, in addition to the economic and design advantages offered by 3D printing compared to traditional metal machining.
Why This Development Is Important for the Space Sector
This shift represents a fundamental transition from proof-of-concept to industrial maturity. In high-volume satellite architectures, such as phased-array payloads, components may be used hundreds of times in a single satellite and across hundreds of satellites within a single constellation. This means that any savings in mass and cost at the component level will translate into massive gains for the entire space program.
The company has proven its technology's space-readiness by subjecting models to Low Earth Orbit (LEO) environment tests, including outgassing, thermal shock, radiation, mechanical stress, and atomic oxygen exposure tests.
New Horizons and Future Applications
The company's ambitions are not limited to shielding housings; it seeks to expand the use of this technology in other space and terrestrial applications where printed and metal-coated polymers can address manufacturing constraints or volume requirements. The company invites the space community to collaborate on developing early concepts, as the IP-MASS platform enables "Design-for-manufacturability" decisions to be made in the early stages of component development.