ROBOZE Helps NESST Build 3D-Printed CubeSat Structure for Space Mission

Italian Startup 3D Prints Verified CubeSat Structure

Italian aerospace startup NESST Srl has designed, additively manufactured, and validated a CubeSat 3U structure using ROBOZE's ARGO 500 platform and Carbon PEEK. The project was funded by the Italian Space Agency and the European Space Agency.

The team used fused filament fabrication to produce structural components. Rigorous testing showed the printed parts deliver mechanical performance comparable to conventional aluminum alloys. The material also met the strict outgassing requirements defined by the ECSS-Q-ST-70-02C standard.

By moving from subtractive manufacturing to 3D printing, NESST gained extreme geometrical customization. ROBOZE supported the project by defining optimal printing parameters during testing, ensuring the material met stringent space industry standards.

Proving that FFF-processed polymers can rival traditional aluminum alloys marks a shift in how we conceive satellite manufacturing. This project validates additive manufacturing as a strategic tool for extreme structural customisation and cost-efficiency. We are already focusing on Phase 2, where we will use this design freedom to embed more functions directly into the CubeSat structures, integrating harnesses, electronics, and microfluidics.

Alessio Lorusso, Founder and CEO of Roboze, added that optimizing the FFF process for high-performance polymers is exactly what their technology is built for. He said the project highlights the readiness of these materials for the evolving space economy.

Last month, Airbus qualified the ROBOZE ARGO 500 HYPERSPEED platform for secondary structural parts. ULTEM 9085 material met Airbus requirements for mechanical performance, flame retardancy, repeatability, process control, and traceability.

This news shows high-performance polymers are moving from laboratory curiosities to flight-qualified hardware. For satellite makers, the appeal is clear: lighter parts, faster iterations, and designs that would be impossible to machine.