Metallized polymers instead of solid metal: Horizon showcases micro 3D printing for RF and mmWave

Horizon is using Space Tech Expo Europe in Bremen (November 18–20) to present its microstructured photopolymer manufacturing with downstream metallization for space applications. The focus is on RF and mmWave components such as antennas, filters, waveguides, and shielded housings, which promise significant mass savings compared to solid-metal components while offering comparable electrical performance. CEO Andreas Frölich will give a talk on Wednesday, November 19, at 14:00 in the Technology Forum titled “Unlocking weight- and cost-savings for Smallsats/New Space/Cubesats by replacing metal with metallised polymer,” and will be present at the ESA SME booth Q27.

Technically, Horizon combines photopolymer micro 3D printing with a proprietary metallization step. The parts are said to deliver high conductivity, tight dimensional tolerances, and—depending on geometry—40 to 80 percent weight reduction compared to solid metal. For orbital use, the company cites passed environmental tests, including outgassing, radiation, humidity, thermal cycling, and atomic oxygen.

“Space Tech Expo gives us a perfect platform to show that we’re no longer talking theory,” says Frölich. “We’ve passed the industry’s toughest environmental tests and we’re ready to engage with partners who need functional, weight-saving alternatives to solid metal components, without compromising reliability.”

The primary audience includes Smallsat, Cubesat, and NewSpace players seeking short development cycles and low launch masses. According to Horizon, manufacturing in polymer with targeted metallization also facilitates geometric adaptations and co-design, for example for impedance-critical transitions, integrated mounts, or thermal interfaces.

“We’re especially eager to meet smaller space players who might not yet know what’s possible,” adds Frölich. “With our recent qualification data and the ability to co-design components for robustness and performance, we think the timing is right to open new collaborations.”

With the current qualification data and the capability for application-oriented design, Horizon believes the conditions are in place to establish metallized polymer components as an option for near-series RF assemblies. Visitors can schedule appointments via the website or drop by booth Q27.