NESST Srl Validates Roboze High-Performance FFF Polymers for Next-Generation CubeSats in ESA-Funded Project
The innovative startup demonstrates that 3D-printed Carbon PEEK components match the mechanical performance of traditional aluminium alloys, proving their readiness for next-generation space applications.
Bari - Italy, August 4, 2026
NESST Srl, an innovative startup dedicated to 3D aerospace manufacturing, announces that has successfully completed the first phase of a project funded by the Italian Space Agency (ASI) and European Space Agency (ESA), focused on the design, additive manufacturing, and validation of primary CubeSat 3U structure using the Roboze ARGO 500 platform and Carbon PEEK. The project’s primary objective was to validate the use of high-performance polymers processed via FFF (Fused Filament Fabrication) for space structural components. Through rigorous testing and material characterization, NESST Srl demonstrated that the Carbon PEEK polymer delivers mechanical performance comparable to the classic aluminum alloys traditionally utilized for satellite structures. Additionally, the material proved fully compatible with the space environment, successfully meeting the strict outgassing requirements defined by the ECSS-Q-ST-70-02C standard.
By transitioning from conventional subtractive manufacturing to advanced 3D printing, NESST Srl has unlocked the potential for extreme geometrical customization. This structural optimization allows for highly tailored designs without incurring the standard tooling costs and rigid constraints associated with CNC machining.
To manufacture the components and support the demanding material characterization campaign, NESST Srl utilized Roboze's advanced additive manufacturing technology and proprietary Carbon PEEK material. Furthermore, Roboze, the company building the Physical AI backbone for autonomous manufacturing, contributed its specialized expertise by supporting the definition of optimal 3D printing parameters during the crucial testing phase, ensuring the material met stringent space industry standards.
"Proving that FFF-processed polymers can rival traditional aluminum 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 customization and cost-efficiency. We are already focusing on Phase 2 of the project, where we will leverage this design freedom to increasingly functionalize the CubeSat structures, directly integrating elements such as harnesses, electronics, microfluidics etc." 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. Optimizing 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." said Alessio Lorusso, Founder and CEO of Roboze.
Disclaimer: This activity was carried out under a programme of, and funded by, Italian Space Agency and European Space Agency. The view expressed in this publication can in no way be taken to reflect the official opinion of the Italian Space Agency and European Space Agency.