9–11 Sept 2025
ESA/ESTEC
Europe/Amsterdam timezone

Additive Manufacturing for Thermal Management Components: Potential, Best Practices, and Space Applications

11 Sept 2025, 14:30
30m
Newton 2

Newton 2

thermal control technologies Thermal Control

Speaker

Mr Daniele Da Prato (Sales Manager at AM Solutions srl)

Description

Metal Additive Manufacturing, particularly Laser Powder Bed Fusion (L-PBF), is emerging as a key technology for producing high-performance components by overcoming the constraints of traditional manufacturing methods. Its design freedom enables the creation of complex, weight-optimized structures, an essential advantage in the aerospace sector.
Components such as structural brackets, lightweight assemblies, waveguides, and heat exchangers are especially well-suited to L-PBF. Heat exchangers, in particular, benefit from geometries that maximize surface area for thermal transfer, such as internal channels, implicit structures, and fine fins, which are difficult or impossible to fabricate using conventional techniques.
This workshop will showcase practical case studies and technical results, providing a comprehensive overview of the L-PBF process chain. Topics will include design optimization strategies, key post-processing steps, and recommended best practices for achieving high-quality metal parts. A dedicated session will focus on the challenges and requirements of 3D printing for space applications, with particular emphasis on the European Cooperation for Space Standardization (ECSS) guidelines that govern flight-ready hardware qualification.
The session aims to offer a clear introduction to L-PBF for engineers and designers new to the technology, while also providing valuable insights for experienced users. Through both technical and regulatory perspectives, the discussion will highlight how Additive manufacturing can be effectively integrated into current and future space missions.

Author

Mr Daniele Da Prato (Sales Manager at AM Solutions srl)

Co-authors

Mr Federico Larini (Project Manager at Am Solutions srl) Ms Giulia Toro (Project Manager at Am Solutions srl) Ms Rebecca Maron

Presentation materials