Introduction

In recent years, replacing metals with advanced polymers and composites has evolved from being a simple alternative to becoming a strategic choice in regulated industries such as aerospace, railway, and energy. The benefits go far beyond weight reduction, including increased efficiency, simplified supply chains, regulatory compliance, and new design possibilities.

Thanks to additive manufacturing and the evolution of materials like Carbon PEEK and Carbon PA PRO, companies can now produce components with superior performance compared to metals, especially when lightweighting, mechanical strength, thermal stability, and electrical or chemical insulation are required.

Why metals are no longer enough

For many years, metal alloys have been the only option in regulated applications. But conditions have changed:

·       Long lead times and rising costs.

·       Manufacturing limitations with complex geometries.

·       Excessive weight for aerospace, rail, or mobility systems.

·       Corrosion or instability in humid or chemically aggressive environments.

·       Need for high customization in small batches.

The market now demands alternative materials that combine performance with production flexibility, while remaining compliant with regulations. That’s where super polymers and reinforced composites come into play.

Tangible benefits of metal replacement

Here are some real-world advantages experienced by companies that have adopted Roboze to replace metal parts:

1. Weight Reduction
In aerospace, structural components in Carbon PEEK for civil and military helicopters have led to weight reductions of up to 40%, immediately improving fuel efficiency, range, and safety.

2. Better Thermal and Chemical Insulation
In pharma and packaging systems, replacing metal with PEEK or ULTEM™9085 has improved resistance to moisture, chemicals, and sterilization processes, extending part lifespan.

3. Customization and Small Batches
Industries such as geothermal energy and railway often face the need to replace obsolete parts. With additive manufacturing and technical materials, it’s possible to produce unique components quickly and with equal or better performance.

4. Compliance and Traceability
Roboze materials are engineered for regulated environments and compatible with standards such as EN 45545 and ASTM E595. This enables the use of composites in safety-critical contexts.

Current application fields

·       Aerospace: structural parts, lightweight brackets, onboard electronics enclosures

·       Railway: retrofitting discontinued components, ducts, and lightweight mounts

·       Energy: valves, connectors, customized sensors for harsh environments

·       Motorsport: ducts, shells, and brackets replacing aluminum with Carbon PEEK and Carbon PA PRO

Design considerations

Replacing metal with a high-performance polymer or composite is not a “plug-and-play” operation. Simply replicating the geometry of a metal part is not enough, unlocking the full potential of these materials requires a rethinking of the entire design approach.

Real load and operating condition analysis

Metals often provide an “excess” of strength, resulting in overengineered parts. Advanced polymers require targeted design: it is crucial to accurately assess mechanical loads, thermal stress, and chemical exposure. This enables the identification of critical areas and the adoption of appropriate reinforcement strategies.

Topology optimization and functional lightening

Additive manufacturing offers unmatched design freedom, allowing for geometries that would be impossible with traditional machining. This is where topology optimization comes into play, removing material from non-critical areas while maintaining performance, resulting in lighter, more efficient parts. Often, the part is even stronger because it’s designed around its actual function.

Choosing the right material

Every super polymer or composite has its own mechanical, thermal, and chemical profile.
Carbon PEEK, for example, offers extremely high thermal and mechanical resistance, ideal for structural applications in extreme environments. Carbon PA PRO combines rigidity and machinability at a lower cost.
Material selection should be based on a matrix of technical, regulatory, and economic requirements to ensure a true alternative to metal, with no compromises.

Validation and testing

Components made from advanced materials must undergo functional validation through FEM simulations, physical testing, and printed prototypes. This is a critical step in industries such as aerospace, railway, and medical, where compliance with safety and quality standards is non-negotiable. In many cases, Roboze supports customers during this phase, from design to validated prototype, ready for industrialization.

With a technology partner like Roboze, offering deep expertise in materials and advanced additive manufacturing, it’s possible to smoothly and efficiently integrate this new approach, helping companies transition from metal to more sustainable, high-performance solutions.

Contact Roboze experts to evaluate the replaceability of your metal components.