As part of its expansion, Sintavia purchased a second SLM NXG XII 600 printer. (Photo: Business Wire)

Sintavia is investing $25 million in facilities and equipment to support future demand from its customers.

HOLLYWOOD, Fla.—Aerospace component manufacturer Sintavia, LLC is carrying out what the company calls its “single largest expansion in facilities and equipment since 2019.” The $25 million investment is expected to enable Sintavia to “meet the demand from the programs it supports across the U.S. Department of Defense for the balance of this decade,” the company said in a release.

The investment in Sintavia’s Hollywood facilities is reported to include the addition of advanced manufacturing space, large format printers, large format post-processing equipment, and component testing equipment.

“Looking into the next few years, it is clear to us that we need to make the investments today that will support the demand from our customers tomorrow,” said Brian Neff, Sintavia’s founder and CEO, in the release. “As the world’s first truly all-digital aerospace component supplier, Sintavia is in a unique position to push the boundaries of what is possible in terms of designing and manufacturing next generation aerospace components along a single, fully digital thread. But to do that, you need first to have the right facilities, hardware, and software in place. That is what we are doing today in support of our customers and their critical programs.”

A major focus of Sintavia’s expansion will be the continued design and development of high-performance thermodynamic components, particularly aerospace heat exchangers. Sintavia’s heat exchangers, enabled using additively designed triply periodic minimal surface structures, are said to demonstrate improved heat rejection at comparative flow rates when evaluated against traditional versions. In addition, the manufacturing sturdiness of a fully digital thread results in production yields close to 100 percent—multiples higher than manufacturing yields often experienced by traditional heat exchanger manufacturers, the company said in the release.

As part of the expansion, Sintavia signed a long-term lease on an additional 25,000 square feet of manufacturing space adjacent to its existing headquarters. The space will be used for printing, post-processing, and materials testing.

New equipment to be added during the expansion includes Sintavia’s second SLM NXG XII 600, a third AMCM M4K-4, a second CT Scanner (450 kV), a second large air furnace, cold flow test machine, and a shock and vibration table. Also included are pressure cycle testing equipment, acoustic testing equipment, multiple additional 5-axis CNC machines, multiple additional fatigue rigs, and multiple additional polishing machines.

Sintavia reported last October that it is also the North American launch customer for the AMCM M8K-K, said to be the world’s largest industrially viable laser powder bed fusion printer, with a cubic displacement of 38 cubic feet.

The expansion is expected to be completed by the fourth quarter of 2024, the company said.