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Manufacturing

Sintavia is the largest pure-play additive manufacturer of advanced propulsion systems for flight and launch OEMs globally.

The company’s products include rocket thrust chamber assemblies, high performance heat exchangers, turbomachinery components, advanced fuel systems, and high-performance combustor assemblies. As the implementation rate of AM accelerates through the aerospace industry, Sintavia has emerged as the leader for AM production of these critical assemblies.

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Printing

On its 26 high production industrial printers, we additively manufacture using proprietary metal parameter sets for Nickel, Copper, Titanium, Aluminum, and refractory metals.

Sintavia’s 55,000 ft2 production facility was built around lean production principles, one of the very first AM factories of its kind to do so.

Eight EOS M400-4 laser machines
Two EOS M400-1 laser machines
Five EOS M290 laser machines
Two AMCM M4K-4 laser machines
One TRUMPF TruPrint 3000 laser machine
Three SLM Solutions 280HL twin laser machines
Three Arcam Q20+ electron beam machines
One Concept Laser M2 laser machine
One Arcam A2X electron beam machine

Furnacing

For most critical aerospace applications, hot isostatic pressing (HIP) and vacuum heat treatment are required to remove porosity of the finished part, increase ductility, and reduce fatigue damage.

Sintavia operates both a hot isostatic press and multiple vacuum heat treat furnaces in-house. After stress relief, all parts must be removed from the build plate after production, and Sintavia uses wire electric discharge machines and bandsaws for this task.

Machining

Although powder bed fusion parts come out of the machines with a remarkable near net shape, post-processing is often involved to meet critical dimensions and/or surface finishes. 

Sintavia utilizes a wide array of final machining methods to meet or exceed customers’ expectations. The company uses multi-axis vertical machine centers, lathes, and traditional mills – all on site – to machine final tolerances.

Surface Finishing

Sintavia is a global leader in the development and implementation of surface finish techniques and processes that conform to aerospace quality standards.

Sintavia’s surface finishing equipment includes wet and dry blasters, multi-vibrating systems, disk finishers, and exude hones. 

Sintavia is a vertically-integrated AM operation, with printing, furnacing, machining, and surface finishing machines and tools all located on-site.