Context: lightweight engineering as a design lever

In the aerospace industry, the mass of each component represents a critical design variable.
Even a modest reduction, on the order of 1 kg, can generate fuel savings and increased payload capacity, with immediate economic impact.

According to NASA estimates published in  “The Recent Large Reduction in Space Launch Cost”, launching payloads to LEO (Low Earth Orbit) with a Falcon 9 costs approximately USD 2,720 per kilogram, based on a 22,800 kg mission valued at USD 62 million. For a 500 kg satellite, reducing just 1 kg of mass translates into a saving of roughly USD 2,700, along with gains in autonomy and payload efficiency.

In this context, additive manufacturing with Roboze superpolymers emerges as an industrial solution for reducing weight, simplifying assemblies, and improving sustainability.
Materials such as Carbon PEEK and ULTEM™ AM9085F, processed on the ARGO 500 HYPERSPEED platform, enable the production of integrated, lightweight structures, eliminating the geometric constraints and fasteners typical of metal manufacturing processes.

3D sandwich structures: a case of applied engineering

A tangible example of this transition comes from the University of Campania “Luigi Vanvitelli”, in collaboration with Roboze, which developed 3D-printed aerospace sandwich structures using the ARGO 500 HYPERSPEED platform.

The goal was to replace traditional metallic panels with a monolithic Carbon PEEK structure, integrating skins and honeycomb core in a single process.
The use of a polymer matrix composite combined with the elimination of adhesives and mechanical joints achieved a 52% mass reduction while maintaining stiffness comparable to metal, stable above 200 °C.

Roboze Carbon PEEK: material properties and system performance

The results of the Vanvitelli–Roboze case study are consistent with the official Roboze Carbon PEEK datasheet (available for download).

To assess its real impact, it is essential to distinguish between material properties and printed component performance.

A) Material property comparison

B) Structural performance – printed sandwich panel

Numerical analysis and interpretation

Roboze Carbon PEEK, tested in XZ orientation per ASTM D790, shows a flexural strength of 124.6 MPa and modulus of 9.74 GPa, values that describe the real behavior of a 3D-printed component, including interlayer response.

Although lower than metals in absolute terms, these values, combined with half the density (1.41 g/cm³) and thermal stability beyond 250 °C, yield an exceptionally high strength-to-weight ratio, enabling the substitution of aluminum in many secondary aerospace structures.

Roboze’s technology, through topological optimization and geometric continuity, maintains global stiffness and strength while reducing overall component mass by up to 50% and assembly costs by 30%, delivering tangible gains in production efficiency and sustainability.

Economic simulation: the value of weight reduction

Each kilogram saved in orbit represents about USD 2,700 in direct savings, plus additional logistical and manufacturing benefits.
Roboze additive manufacturing converts weight reduction into a quantifiable economic advantage, enhancing efficiency and sustainability throughout the mission lifecycle.                

Roboze Carbon PEEK: composite material for extreme performance

Tested according to ASTM E595 and ESA ECSS-Q-ST-70-02C, Roboze Carbon PEEK demonstrates exceptionally low outgassing performance.

Source: Roboze White Paper – “Outgassing Behavior of Carbon PEEK” (ARGO 500 HYPERSPEED).

Values two orders of magnitude below NASA limits confirm compatibility with optical payloads, satellite structures, and avionic components.

Engineering advantages:

• Thermal stability beyond 250 °C

• Specific strength > 120 MPa·cm³/g

• Vacuum-grade compatibility without coatings

• Reduced anisotropy through orientation control

• Excellent chemical and dimensional stability

ULTEM™ AM9085F: the certified aerospace solution

ULTEM™ AM9085F, a high-performance amorphous thermoplastic (PEI-based), combines lightweight, rigidity, and thermal stability up to 175 °C.
It is certified for aerospace use through FAA FAR 25.853 and OSU 55/55 tests, confirming its FST (Flame, Smoke, Toxicity) compliance.
The full datasheet is available on the Roboze ULTEM™ AM9085F page.

ULTEM™ AM9085F is ideal for brackets, ducts, electronic housings, and interior aircraft components in pressurized cabins, due to its dielectric stability and chemical resistance in demanding environments.

Comparative table: Roboze materials for aerospace

Conclusion: structural efficiency and competitive advantage

Thanks to Roboze superpolymers and the ARGO 500 HYPERSPEED platform, the aerospace industry can now combine weight reduction, high mechanical performance, and environmental compliance with the most stringent standards.

Adopting Carbon PEEK and ULTEM™ AM9085F enables:

• Up to 50% weight reduction vs. metals

• Lower fuel-burn emissions

• In-house certified production with reduced lead time

Roboze additive manufacturing is redefining lightweight design in aerospace, bringing the precision and reliability of superpolymers to levels once achievable only with metals.

Contact the Roboze Aerospace team today for a free technical-economic evaluation.