Metal-coated micro 3D-printed parts pass radiation test for orbital applications

Horizon Microtechnologies reports a significant step in qualifying its metal-coated, micro–additively manufactured components. In a validation program, the parts withstood simulated radiation exposure equivalent to roughly four years of operation in low Earth orbit. The aim was to assess the adhesion strength of the electroplated metal layers on polymer substrates as well as the aging behavior of the base material under ionizing radiation.

The results address two key questions for spaceflight qualification. First, the coating remained fully adhesive and structurally intact throughout the exposure period; no delamination or cracking was observed. Second, the polymer showed an increase in brittleness, as expected. Whether this embrittlement is critical depends, according to Horizon, on part geometry, load spectrum, and use case. The measurement data feed into simulation models that can be used to determine permissible operating limits for specific parts. Of practical relevance is the fact that the highest mechanical loads typically occur during the rocket launch—i.e., before any significant radiation dose has been accumulated.

Andreas Frölich, CEO of Horizon, comments, “This is about delivering proof, rigorous, transparent, and relevant. Our data shows that coated polymer parts can perform reliably even in high-radiation environments, making them increasingly viable for space missions.”

Frölich adds, “Each successful test expands the envelope of where and how our technology can be used. We’re not just qualifying parts, we’re enabling new possibilities.”

The technology combines precise micro AM with high-performance metal coatings to provide electrical conductivity, reduce mass compared to all-metal constructions, and enable highly complex geometries. In addition to the radiation test, thermal cycling and outgassing have already been passed successfully, underscoring suitability for vacuum- and temperature-critical environments. For scenarios where post-irradiation brittleness could remain critical, Horizon offers application-specific support, such as geometry adjustments to reduce stresses after exposure.

With the new data, Horizon expands the deployment envelope of metalized micro 3D-printed parts in satellite development. The combination of experimental evidence and simulation-driven design provides a basis for targeted qualification of functional parts in onboard electronics, sensing, or RF guidance—and for shortening time to mission approval.