Sintavia designs and additively manufactures thermomechanical systems and components for the Aerospace, Defense, & Space industry, including heat transfer systems, propulsion systems, power generation components, and scalable cooling cores.

The company’s design engineers are experts in thermal modeling, finite element analysis, computational fluid dynamics, CAD, and conformity testing. Thermomechanical systems designed and additively manufactured by Sintavia are lighter weight and better performing than traditionally designed and manufactured versions.

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Thermodynamic Systems

AM has long been recognized as a natural production process for thermodynamic systems such as heat exchangers and chassis, given AM’s ability to create internal passageways in geometries that can’t be manufactured by traditional methods.

Sintavia’s expertise in thermal modeling allows it to manufacture both low temperature (up to 250⁰ C) and high temperature (up to 800⁰ C) heat exchangers and chassis with increased heat transfer coefficients and minimal pressure drop penalties. These heat exchangers and chassis can be manufactured with internal walls of 150 microns or less, and are more than 40% lighter weight than traditional models.

Thrust Chamber Assemblies

Sintavia works with its commercial space launch and defense customers to design via AM thrust chamber assemblies that meet and exceed customer mission requirements. With an unparalleled AM capability for mass production, Sintavia is able to design rocket engines that are exceptionally cost effective and powerful. Currently, Sintavia specializes in rockets designed with less than 100,000 lbf, using both liquid and solid fuel configurations.

Sintavia’s ability to design and print systems that fit within an envelope of 450mm x 450mm x 1000mm, combined with its leading manufacturing technology in printing in copper and nickel alloys, allows the company to manufacture highly complex, monolithic propulsion systems that are impossible to produce traditionally.

Turbomachinery Components

Sintavia is one of very few companies globally that has built an aerospace quality management system centered solely on additively manufactured, commercial aerospace components. As a result, Sintavia is one of very few aerospace manufacturers that is able to 3D print certified, flightworthy turbomachinery components for manned flight.

The commercial turbomachinery market is enormous, and as AM adoption accelerates, Sintavia’s leading position in 3D printing these critical components will grow.

Advantages of AM

These designs can offer substantial weight savings and performance in modern aerospace advanced system and assembly design. Each design is manufactured from electronic data generated from CAD files making it a fully direct digital manufacturing process.

Since the design is controlled directly from a CAD file, AM can produce parts that were at one time impossible to manufacture by conventional processes such as cutting, grinding and drilling.

The design is only limited by a designer’s creative abilities. Features such as conformal cooling inserts, functional integration, complex geometries, lattice networks and hollow members are now produced with considerable ease via the AM process.