Thaero offers a hybrid manufacturing process that merges supersonic cold spray with solid‑state metal 3D printing to produce aerospace‑grade metal‑matrix nanocomposites at up to 1,000× the speed of conventional beam‑based printers. The platform uses AI‑driven material informatics to accelerate the development of BNNT‑reinforced alloys and enables embedding sensors and dissimilar materials in open‑atmosphere, near‑net‑shape builds for defense, space and nuclear applications.
Funding
Funding not disclosed
Founders
Product
Problem
Current manufacturing methods for high‑performance aerospace and defense components rely on slow, high‑energy processes that cannot easily incorporate nanomaterials, multi‑material structures, or embedded sensors, limiting the ability to produce lightweight, high‑strength, high‑temperature parts at scale.
Solution
Thaero combines supersonic cold spray with solid‑state additive manufacturing to create a high‑deposition‑rate hybrid process capable of printing aerospace‑grade metal‑matrix nanocomposites. The process integrates boron nitride nanotubes (BNNTs) into alloys, delivering superior strength, ductility, wear resistance, thermal conductivity, neutron absorption, and stability above 850 °C. An AI‑driven informatics platform accelerates material discovery through molecular dynamics simulations and machine‑learning‑guided high‑throughput experimentation, enabling rapid prototyping of novel superalloys. The solid‑state printing approach operates in open atmosphere, allowing near‑net‑shape builds up to 1,000 × faster than conventional beam‑based metal 3D printing, while supporting the embedding of hardened sensors, electronics, and dissimilar material combinations. This capability supports the production of lightweight structural parts for defense, space, nuclear, and high‑temperature applications.
Target Audience
Primary customers are defense contractors, aerospace manufacturers, space agencies, and nuclear industry firms that require high‑performance, lightweight, and sensor‑integrated metal components.
Features
- Hybrid manufacturing that merges supersonic cold spray with solid‑state metal 3D printing for ultra‑high deposition rates
- AI‑driven nanomaterials informatics platform for accelerated discovery and high‑throughput experimentation of BNNT‑reinforced alloys
- Ability to embed sensors, electronics, and combine dissimilar materials (ceramics, nanoparticles, fibers) within printed components
- Open‑atmosphere solid‑state printing that operates up to 1,000 × faster than traditional beam‑based metal 3D printing
- Production of nanocomposites with enhanced mechanical strength, ductility, wear resistance, thermal conductivity, neutron absorption, and stability above 850 °C
- Scalable process without vacuum chambers, enabling large‑format builds and rapid repair of damaged structures