Italian Startup 3D-Prints a CubeSat Structure in Carbon PEEK, Passes Space Standards

Italian aerospace startup NESST Srl has completed the first phase of an Italian Space Agency and European Space Agency-funded project to 3D print and validate a primary CubeSat 3U structure. The part was printed on a Roboze ARGO 500 HYPERSPEED using Carbon PEEK, a high-performance polymer composite. Testing showed the FFF-printed structure matches the mechanical performance of conventional aluminum alloys used in satellite manufacturing, and the material passed strict European Cooperation for Space Standardization outgassing requirements.

Polymers vs Aluminum in Space

Satellite structures have traditionally been machined from aluminum alloys. Those materials are proven and well understood, but they come with trade-offs: heavy, expensive tooling, long lead times, and limited geometry freedom. NESST's project was designed to prove that high-performance polymers processed via Fused Filament Fabrication could deliver equivalent strength while enabling lighter, more customizable designs.

Carbon PEEK delivered on that promise. The material met ECSS-Q-ST-70-02C outgassing limits, a critical hurdle for any material used inside a spacecraft. That means it does not release excessive volatile compounds in the vacuum of orbit, which could interfere with sensitive electronics or optics.

Design Freedom and Phase 2

Shifting from CNC machining to 3D printing removes the constraints of tooling. NESST technical manager Francesco Lucia said the project validates the idea that additive manufacturing is a strategic tool for extreme structural customization and cost efficiency. The team is already moving into Phase 2, where it plans to embed harnesses, electronics, and microfluidic systems directly into the 3D-printed structure, taking advantage of geometries that would be impossible to machine.

Roboze's Role

Roboze provided both the ARGO 500 HYPERSPEED printer and technical support to define optimal printing parameters for the demanding space environment. Roboze founder and CEO Alessio Lorusso said the project highlights the readiness of high-performance polymers for the evolving space economy. Last month, Airbus separately qualified the same Roboze platform and ULTEM 9085 material for secondary structural parts, adding momentum to the case for polymer AM in aerospace.

For small satellite builders, the implications are straightforward. A 3D-printed polymer structure that passes space-qualification testing means faster prototypes, lower production costs, and the ability to integrate more function into less mass.