Scottish PocketQube satellite manufacturer AlbaOrbital has completed its second launch of four 3D-printed carbon fiber satellites from Rocket Lab's Launch Complex 1 Pad A on New Zealand's Māhia Peninsula. The "Alba Cluster X" mission deployed 4 out of 34 PocketQube satellites using Alba's advanced 3D-printed "AlbaPod v2" system, manufactured with CRP Technology's carbon fiber-reinforced Windform XT 2.0 composite material and laser powder bed fusion technology.
Advanced Manufacturing Process
The satellites were produced using selective laser sintering (SLS), with CRP Technology enhancing the process through its proprietary Windform materials. The AlbaPod v2 deployment system – including its casing, ejection mechanism, and components – was redesigned specifically for 3D printing.
Material Certification
Windform XT 2.0's carbon fiber reinforcement enables both functional prototypes and end-use parts. Certified as "HB" in UL94 flammability testing, the material meets critical thermal resistance and flame-retardancy requirements for aerospace applications near thrusters and booster flames.
Proven Track Record
AlbaOrbital began utilizing Windform XT 2.0 in 2020 for its superior mechanical and thermal properties. Prior to the December 2020 third mission launch, the company successfully integrated nine PocketQube satellites into an AlbaPod v2 system, demonstrating the technology's space readiness.
Technical Implementation
Industrial 3D printing with laser powder bed fusion
Flight-certified carbon fiber composite structures
Mission-proven deployment mechanisms
This achievement confirms the viability of 3D-printed carbon fiber components for orbital applications, marking a significant step in cost-effective satellite manufacturing. AlbaOrbital's continued adoption of Windform materials underscores the growing role of additive manufacturing in space technology development.
