3DPTimes — One World Printed Together

Login Signup

Home > Materials

AOA Xinetics Launches World's First 3D-Printed Silicon Carbide Aerospace Optical Components

September 18, 2025 Materials 239

Northrop Grumman has pioneered the first space-certified 3D printed silicon carbide optics using its proprietary CERAPRINT process, marking a breakthrough for aerospace and defense applications.

3DPTimes has learned that AOA Xinetics, a Northrop Grumman subsidiary, has developed CERAPRINT—a proprietary additive manufacturing process based on Desktop Metal’s X-Series binder jetting system—enabling the 3D printing of silicon carbide optical components. This technological advancement has led to the creation of the first 3D-printed silicon carbide optical component to fly in space, marking a historic milestone for both manufacturing and mission reliability.

This breakthrough represents a paradigm shift in the manufacturing and deployment of high-energy laser systems and space optics. By integrating precision engineering, superior materials, and cost efficiency, Northrop Grumman is laying the foundation for the next generation of advanced defense systems.

Application of AOA Xinetics in Defense Innovation

AOA Xinetics (often abbreviated as AOX) is renowned in the fields of adaptive optics and high-precision optical systems. For decades, the company has supported national security missions demanding the highest levels of reliability and performance. With the introduction of CERAPRINT, AOX is moving beyond traditional optical engineering into a new era where complex designs can be realized faster, more economically, and with unprecedented flexibility.

Silicon carbide (SiC), a hard ceramic material composed of silicon and carbon, offers exceptional strength, durability, and thermal resistance. Its unique structure ensures extreme stability even under high-stress conditions. Unlike conventional optical materials, silicon carbide maintains predictable and uniform performance despite extreme temperature fluctuations or mechanical stress, making it an ideal choice for space missions and directed energy systems.

AOA Xinetics has developed reaction-bonded silicon carbide (SiC) tailored for optical applications. This SiC material can be polished to high precision, is lightweight, and has been certified for critical national security missions. Its stability ensures reliable operation in some of the most demanding environments.

The CERAPRINT Process

CERAPRINT is Northrop Grumman’s proprietary additive manufacturing method for producing SiC optical components, based on Desktop Metal’s X-Series binder jetting technology. By moving away from labor-intensive traditional processes, CERAPRINT reduces complexity and allows engineers to directly print silicon carbide components into highly intricate geometries. This process offers unparalleled design freedom, enabling the creation of shapes and configurations that were previously too costly or impossible to manufacture.

CERAPRINT also enhances efficiency throughout the production cycle. Prototypes that once took months to develop can now be completed in just days, while the lead time for finished components is significantly reduced. In addition to faster production, costs are substantially lower—often by up to 70% compared to conventional methods. Rapid development, reduced costs, and superior performance are why this technology is hailed as transformative.

The First 3D-Printed SiC Optical Component in Space

The CERAPRINT process has proven its practical applicability. Northrop Grumman successfully produced the first certified 3D-printed silicon carbide optical component for use in space. This achievement is significant because the space environment demands absolute reliability. To meet these standards, the optical component was tested to Technology Readiness Level (TRL) 9—the highest level confirming operational maturity.

By reaching TRL 9, Northrop Grumman has demonstrated that 3D-printed SiC optics are not merely an experimental concept but a flight-proven technology capable of withstanding the rigors of orbital missions.

High-energy laser systems heavily rely on the precision and durability of optical components. Integrating 3D-printed SiC optics into these systems offers several critical advantages. The mechanical stability of silicon carbide ensures exceptional precision in laser beam output, even during prolonged high-power operation. Additionally, SiC optics’ ability to tolerate extreme temperatures makes them a natural choice for high-energy laser applications, where thermal management remains a persistent challenge.

Perhaps most importantly, CERAPRINT technology supports the scalability of High-Energy Laser (HEL) systems. With lower manufacturing costs and faster production cycles, defense organizations can more easily scale the use of directed energy technology across multiple platforms. This scalability is critical as military forces seek to deploy HEL systems for a variety of missions, including missile defense, counter-drone operations, and next-generation battlefield capabilities.

Material Advantages of AOX CERAPRINT SiC

In addition to mechanical strength, silicon carbide produced via CERAPRINT offers a range of benefits. The component’s low coefficient of thermal expansion enables it to withstand significant temperature variations without deformation, while its high thermal conductivity ensures efficient heat management. These properties are particularly vital in space environments and directed energy applications, where precision is non-negotiable.

Furthermore, silicon carbide’s low porosity and predictable uniformity ensure consistent performance across multiple production batches. Its electrical properties also make it suitable for charged environments, further enhancing its versatility as a material of choice for advanced defense and aerospace systems.

Implications of 3D-Printed SiC Optics

The successful deployment of 3D-printed silicon carbide optics has profound implications for the future of defense, space exploration, and even commercial industries. In military applications, the ability to mass-produce high-performance optics at lower costs and shorter lead times will enable faster deployment of advanced high-energy laser systems across multiple domains. Directed energy weapons are expected to play a key role in future battlefields, and scalable optics are a critical enabler of this vision.

In space, 3D-printed SiC optics open the door to more complex, lightweight, and resilient optical systems. From satellites and telescopes to deep-space missions, the potential to rapidly and economically manufacture high-performance optics could revolutionize mission design.

Over time, commercial applications are also likely to emerge, particularly in industries requiring optical components with high strength and thermal stability. Fields such as telecommunications, scientific research, and advanced manufacturing could benefit from the precision and durability of Northrop Grumman’s CERAPRINT SiC optics.