ROBOZE Helps NESST Build 3D-Printed CubeSat 3U Structure

Italian aerospace startup NESST Srl has designed, additively manufactured, and validated a CubeSat 3U structure using the ROBOZE ARGO 500 platform and Carbon PEEK filament. The work was carried out as part of an Italian Space Agency and European Space Agency funded project, with rigorous testing showing that Fused Filament Fabrication delivers mechanical performance comparable to conventional aluminium alloys.

Meeting space-grade requirements

The Carbon PEEK material used in the build met the strict outgassing requirements defined by the ECSS-Q-ST-70-02C standard. That is a key hurdle for any polymer used inside a satellite, where even small amounts of released gas can fog optics or disturb sensitive instruments. Passing that test puts the material in a very small group of desktop-printable polymers qualified for space use.

NESST Srl deployed the ARGO 500 to manufacture the structural components, working with ROBOZE to define the optimal printing parameters during the testing phase. Francesco Lucia, Technical Manager at NESST Srl, said proving that FFF-processed polymers can rival aluminium marks a shift in how satellite structures are conceived. He added that the team is already moving into Phase 2 of the project, where design freedom will be used to add functional elements such as harnesses, electronics, and microfluidics directly into the CubeSat structure.

Industrial validation continues

The news follows last month's announcement that Airbus had qualified the ROBOZE ARGO 500 HYPERSPEED platform for secondary structural parts, with ULTEM 9085 meeting Airbus requirements for mechanical performance, flame retardancy, repeatability, and traceability. That industrial reference, combined with the CubeSat result, gives ROBOZE two strong data points in the high-performance polymer 3D printing market.

For NESST Srl, the advantage of switching from subtractive manufacturing to additive is the ability to produce complex geometries in a single build. Traditional satellite structures require multiple machined parts bonded together. A 3D-printed version can consolidate those parts, cut weight, and reduce assembly time. Whether that translates to cheaper missions depends on scale, but the direction is clear.