Recent improvements in additive layer manufacturing (ALM) have provided new designs of geometrically complex structures with lighter materials and low processing costs. The use of additive manufacturing in spacecraft production is opening up many new possibilities in both design and fabrication, allowing for the reduction of the weight of the structure subsystems. In this aim, polymeric ALM structures can become a choice, in terms of lightweight and demisability, as far as good thermomechanical properties. Moreover, provided that fused-deposition modeling (FDM) is used, nanosats and other structures could be easily produced in space. However, the choice of the material is a crucial step of the process, as the final performance of the printed parts is strongly dependent on three pillars: design, material, and printing process. As a high-performance technopolymer, polyether ether ketone (PEEK) has been adopted to fabricate parts via ALM; however, the space compatibility of 3D-printed parts remains not demonstrated. This work aimed to realize a nanosat polymeric structure via FDM, including all the phases of the development process: thermomechanical design, raw material selection, printing process tuning, and manufacturing of a proof of concept of a technological model. The design phase includes the application of topology optimization to maximize mass saving and take full advantage of the ALM capability. 3D-printed parts were characterized via thermomechanical tests, outgassing tests of 3D-printed parts are reported confirming the outstanding performance of polyether ether ketone and its potential as a material for structural space application.

In the food packaging sector many efforts have been (and are) devoted to the development of new materials in order to reply to an urgent market demand for green and eco-sustainable products. Particularly a lot of attention is currently devoted both to the use of compostable and biobased polymers as innovative and promising alternative to the currently used petrochemical derived polymers, and to the re-use of waste materials coming from agriculture and food industry. In this work, multifunctional eco-sustainable systems, based on poly(lactic acid) (PLA) as biopolymeric matrix, diatomaceous earth as reinforcing filler and spent coffee grounds extract as oxygen scavenger, were produced for the first time, in order to provide a simultaneous improvement of mechanical and gas barrier properties. The influence of the diatomite and the spent coffee grounds extract on the microstructural, mechanical and oxygen barrier properties of the produced films was deeply investigated by means of X-Ray diffraction (XRD), infrared spectroscopy (FT-IR, ATR), scanning electron microscopy (SEM), uniaxial tensile tests, O2 permeabilimetry measurements. An improvement of both mechanical and oxygen barrier properties was recorded for systems characterised by the co-presence of diatomite and coffee grounds extract, suggesting a possible synergic effect of the two additives.