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Pressurized Tanks for Space with WAAM image

The aerospace industry is undergoing rapid innovation, driven by increasing public and private investments and the expansion of the space economy. As demand grows for advanced components and faster production cycles, additive manufacturing is playing a key role in enabling more flexible, efficient, and sustainable processes.

Within this context, Caracol developed a project—supported by the TechFast Lombardia program—to improve the production of space components such as pressurized tanks, contributing to the digital and technological advancement of aerospace manufacturing.01 Pressurized Tanks for Space with WAAM

Production of pressurized tanks with WAAM technology

The project focused on the development of a pressurized aluminum tank designed for carrier satellites used to deploy CubeSats into orbit. These satellites support applications such as research, telecommunications, and monitoring. Caracol leveraged its WAAM technology, based on MIG welding, combined with proprietary 8-axis slicing and control software, to manufacture the component with high precision and efficiency. The project was developed in collaboration with D-Orbit, as end-user, and Politecnico di Milano, supporting material characterization and testing.

In addition, a fully integrated digital workflow was designed to connect engineering, manufacturing, and testing phases, ensuring process control and repeatability.

Production data

  • Technology: WAAM (MIG-based) with proprietary 8-axis control software
  • Material: Aluminum alloy AL2319
  • Application: Pressurized tank for satellite deployment
  • Process: Monolithic metal component, no assembly required
  • Workflow: Integrated digital flow for design, production, and testing

02 Pressurized Tanks for Space with WAAM

Benefits and industrial value

The adoption of WAAM technology for space applications delivers key advantages compared to traditional manufacturing methods:

  • Design freedom: Ability to produce complex, custom geometries without shape constraints
  • Monolithic structures: Single-piece components eliminating assembly of multiple parts
  • Weight reduction: Optimized designs leading to lighter components and lower launch costs
  • Reduced material waste: More efficient use of raw materials compared to subtractive processes
  • Shorter lead times: Faster production cycles for low-volume, high-value components
  • Process digitalization: Full control and repeatability through integrated digital workflows
  • Sustainability: Lower environmental impact thanks to reduced waste and lighter structures

This project demonstrates the potential of WAAM as an emerging technology for the production of advanced aerospace components, enabling more efficient, flexible, and scalable manufacturing processes for the space industry.Caracol-pressurized-tanks

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