The metallization of polymer-based 3D printed parts was long considered a technical risk with limited application potential. Although the concept – complex, lightweight structures with a conductive or reflective metal surface – seems particularly appealing in areas such as high-frequency technology or aerospace, many previous approaches failed due to a lack of adhesive strength, outgassing behavior or mechanical instability. The company Horizon Microtechnologies is now pursuing a data-based approach to specifically address these concerns.
Instead of relying solely on theoretical advantages, Horizon subjects its copper coatings to an extensive test program that takes both environmental and stress factors into account. The tests include resistance to rapid temperature changes, high humidity and vibrations. Outgassing tests are also carried out, which are particularly important for vacuum-relevant applications such as satellite technology. Exposure to atomic oxygen is intended to simulate resistance under conditions in low earth orbit.
“The scepticism in the industry isn’t misplaced, it’s a reflection of real challenges that have stymied previous efforts,” says Andreas Frölich, CEO at Horizon Microtechnologies. “However, we believe that through rigorous testing and transparent results, we can demonstrate that our technology is not just potentially promising — it is precisely proven. We have already shown that our coating technologies deliver high-quality metallic films on 3D printed parts, but now is the time for empirical testing and transparent results on their durability in specific exacting applications.”
By publishing the test results, Horizon aims to create a new reference framework that allows users to make a well-founded assessment of the performance of metallized plastic parts. This could open up new design options, particularly for applications in which conventional metal components are too heavy, too expensive or geometrically impossible to implement. Empirical proof under application-related conditions remains crucial.
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