Aerospace and defense components must perform reliably under extreme thermal, mechanical, and environmental conditions. Low weight, dimensional stability, and material performance are critical in applications ranging from space mirrors and protective ceramics to advanced composite structures.

Siliconized silicon carbide combines low thermal expansion, high stiffness, and resistance to thermal shock, making it suitable for precision and high-temperature applications. Binder jetting enables lightweight internal structures and near-net-shape geometries that reduce material use and machining requirements.

Washout tooling also supports the production of enclosed carbon fiber parts that are difficult to manufacture with conventional rigid molds. Together, these capabilities provide a faster and more flexible route for developing high-performance components for space and defense applications.

Ultra complex

Lightweight, ultra complex parts.

Fast turnaround

Fast turnaround times.

Mechanical strength

Excellent mechanical properties.

Composites & ceramics

For composites and ceramics.

Up to 2 meters

Parts up to 2 meters in size.

Application

Space mirror

Space optics require components that remain stable under extreme temperature changes while keeping weight to a minimum. Space mirrors are a key application for siliconized silicon carbide (SiSiC), as the material combines a low coefficient of thermal expansion with high resistance to thermal shock.

CONCR3DE's binder jetting technology enables the production of highly structured SiSiC mirrors with lightweight internal geometries and dense functional surfaces. A near-net-shape component is printed and ground completely flat, after which the surface can be finished with a Chemical Vapor Deposition (CVD) coating to achieve the required mirror finish.

This application demonstrates how binder jetting can reduce the weight of space mirrors while maintaining the dimensional stability and material performance required for demanding space applications. The process can be transferred to the CONCR3DE Elephant platform to increase production capacity and support higher-volume manufacturing.

Application

Body armor

Ceramic body armour is used in personal protection systems and armored vehicles where high levels of protection must be achieved with minimal weight. Materials such as silicon carbide (SiSiC) and boron carbide combine exceptional hardness with low density, making them well suited for demanding defense applications.

Using CONCR3DE Armadillo printer, ceramic armour inserts can be produced without dedicated tooling. The process supports the manufacture of curved plates, internal lattice structures, and multi-hit tile arrays while enabling rapid design iteration and scalable production.

This demonstrates how binder jetting can support the development and manufacture of lightweight ceramic armour components for both personal and vehicle protection.

Application

Carbon fiber drone body

Carbon fiber drone bodies must combine low weight, structural strength, and aerodynamic performance. Their geometry can include enclosed shapes, smooth external surfaces, and integrated internal features that are difficult to achieve using conventional composite manufacturing methods.

CONCR3DE produced the carbon fiber drone body using a 3D printed washout tool. The water-soluble tool was printed directly from the digital design, the carbon fiber was applied and cured around it, and the tool was then removed with water to release the finished component.

This application demonstrates how binder jetting can support the production of lightweight and geometrically complex carbon fiber parts. It reduces the need for multi-part molds and enables enclosed shapes that would otherwise be difficult to manufacture and demold.

Development and smaller production runs can be completed on the CONCR3DE Armadillo, while the process can be transferred to Elephant to increase tooling production capacity and support higher-volume manufacturing.