Sintavia designs and additively manufactures critical components for the Aerospace, Defense, and Space industry, including rocket thrust chamber assemblies, heat exchangers, high pressure ducts, and chassis.

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

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Rocket Thrust Chamber Assemblies

Sintavia works with its commercial space launch and defense customers to design rocket assemblies using AM that meet and exceed their 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.

Heat Exchangers
AM has long been recognized as a natural production process for heat exchangers, 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 with increased heat transfer coefficients and minimal pressure drop penalties. These heat exchangers can be manufactured with internal walls of 150 microns or less, and are more than 40% lighter weight than traditional models.

High Pressure Ducts

Sintavia additively manufactures precision high pressure ducts and duct assemblies for Aerospace, Defense, & Space applications. AM is uniquely suited to meet the difficult design geometries and tolerances of high pressure ducts, and can manufacture assemblies that require fewer component piece parts. Using computational fluid dynamics software, Sintavia is able to design and additively manufacture ducts with optimized flow.

Chassis, particularly those with internal conformal cooling holes, are natural applications for AM, combining traditionally difficult manufacturing aspects. These include thin walls, internal passageways, and unique geometries. By conforming its expertise in both duct and heat exchanger manufacturing, Sintavia is able to design chassis that cool key electronic components at a reduced weight.

Other Part Families

As AM continues to be adopted, Sintavia will continue to work with its customers to develop successful manufacturing strategies for new part families.

Advantages of AM

These designs can offer substantial weight savings and performance in modern aerospace advanced component 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.