AMSynchro — Space Manufacturing Digital Thread
An ESA-selected software platform establishing a complete digital thread for metal powder in Additive Manufacturing — tracking material genealogy from receipt to recovery with AI-assisted quality assurance.
The Challenge
Aerospace-grade Additive Manufacturing demands absolute traceability. Every gram of metal powder used in space hardware must be tracked: where it came from, how it was stored, which builds it was used in, how much was recovered, and whether it meets the strict quality thresholds for reuse. Without a robust digital thread, quality assurance becomes manual, error-prone, and impossible to audit to aerospace standards.
AMSynchro needed to develop a software platform that could close this loop completely — from material receipt through storage, build usage, and powder recovery — with AI-assisted decision support to flag quality concerns before they become flight risks.
The Approach
We worked closely with the AMSynchro’s team, focusing on two key activities:
- Software/Hardware integration to collect data in embedded environments
- Solutions Engineering work with early adopters and partners to test and improve the platform
The platform was selected by ESA and sponsored thanks to the Technology Broker programme, which requires demonstrated capability against aerospace quality standards.
The Outcome
- Complete digital thread established for metal powder across the full additive manufacturing lifecycle
- Identified and worked closely with a range of key partners and early adopters
- AI-assisted decision support integrated for quality assurance
- Full audit trail meeting aerospace-grade documentation requirements
- Featured in the European Space Agency’s Technology Broker platform
Technologies & Methods
Embedded systems, firmware development, additive manufacturing process integration, AI decision support, aerospace quality assurance frameworks, materials data management.
About this engagement
This was a Transform engagement: development of a complex, safety-adjacent platform with embedded systems integration and AI capabilities, while establishing key partnerships with external stakeholders.