Horizon Microtechnologies has taken a significant step in validating its proprietary metallisation process for precision- and micro-additive manufacturing (AM) polymer parts for space applications. The company’s coated 3D-printed parts have successfully passed outgassing testing in accordance with the ECSS-Q-ST-70-02C standard for screening of space materials, a key requirement for materials and components destined for applications in the extreme environment of space.
The outgassing test evaluated coated plastic micro-AM parts produced by Horizon under thermal vacuum conditions: As described in the testing standard, the specimens were exposed to 125°C in a vacuum range of 10⁻⁶–10⁻⁷ mbar for 24 hours and weighed before and after the process as well as 24 h following the end of the tests. This serves to determine the amount of volatile content released and reabsorbed by the parts. In addition, the amount of material that condensed or otherwise collected on a test plate held at 25°C and located close to the samples was determined to see whether the tested materials could lead to contamination of neighbouring components. This is quantified as Total Mass Loss (TML), Recovered Mass Loss (RML), and Collected Volatile Condensable Material (CVCM), respectively. The results were:
- TML: 0.354%
- RML: 0.166%
- CVCM: 0.000%
These numbers are well within the acceptance limits defined by ECSS-Q-ST-70-02C for materials intended for spacecraft (RML <1.00% and CVCM <0.10%).
“This result is significant for Horizon as further validation that our combination of 3D printed material and coating delivers the level of reliability and material stability needed for applications where failure is not an option,” says Andreas Frölich, CEO of Horizon Microtechnologies. “Historically, coatings on 3D-printed parts have been viewed with scepticism due to challenges such as outgassing, delamination, and surface fragility. With this test, we’ve demonstrated that these barriers can be overcome.”
Outgassing (where trapped gases are released from materials) poses a severe risk in space applications, in which the effect is more pronounced and potentially more harmful due to the vacuum environment than in terrestrial environments. It can lead to contamination of sensitive instruments and degrade material performance, especially coating adhesion. For Horizon, passing this test not only highlights the stability of its metallisation layer but also signals its readiness for mission-critical aerospace applications.
“This milestone is part of our broader strategy to validate our technology across all relevant stress domains, thermal, mechanical, and environmental,” Frölich continues. “We are building a track record of success that we believe will fundamentally shift how engineers think about coating technologies for polymer AM parts.”
Horizon’s approach differs from traditional methods by offering a highly adaptable coating process that conforms to complex geometries typical in AM, enabling design freedom, lightweighting and functional integration for space-grade parts.
“Our vision is to unlock new applications — from precision-printed and coated micro-AM parts to fully functional RF components— that benefit from the design flexibility of additive manufacturing, without compromising on performance,” Frölich concluded. “This is one more proof point that we’re making that vision a reality.”
With outgassing testing successfully completed, Horizon will continue its qualification programme, including vibration, atomic oxygen, and radiation tests, to fully demonstrate the suitability of its coated micro AM parts for space and beyond.