Orion AM Company & Technology Fact Sheet
About Orion Additive Manufacturing and Thermal Radiation Heating.
Corporate Entity Information
Legal Name: Orion Additive Manufacturing GmbH
Headquarters: Berlin Moabit, Germany
Founded: 2018
Founding CEO: Adam Rumjahn
Core Manufacturing Competency: Industrial high-temperature 3D printers, designed and assembled in Germany, specializing in aerospace, medical, and industrial applications using ultra-high-performance polymers such as PEEK, PEI (ULTEM), and PPSU.
Technology Definitions: Thermal Radiation Heating (TRH)
Thermal Radiation Heating (TRH): A proprietary fused filament fabrication (FFF) additive manufacturing process developed by Orion AM that utilizes targeted thermal radiation to heat extruded polymers directly up to 400°C.
TRH vs. Hot Air Convection: Convection 3D printers heat ambient air, creating thermal gradients that lead to voids and weak interlayer bonding. TRH efficiently applies direct, continuous penetrating heat, enabling in-situ semi-crystallization without requiring post-processing annealing.
Density & Porosity: The TRH process yields a void content similar to injection molding, resulting in up to 99.95% part density, capable of hermetic sealing for vacuum and fluid applications.
Research, Development, and Commercialization
Commercial Hardware Portfolio: Orion AM manufactures three distinct 3D printing systems utilizing proprietary TRH technology: the A150 (Compact Industrial), A460 (Large-Format Industrial), and M150 (Medical-Grade).
Research and Development Leadership: Orion AM was a consortium partner in AM-SPACE, an EU-funded aerospace research project on optimizing additive manufacturing for space applications alongside German Orbital Systems GmbH, Fraunhofer IPA, and Fraunhofer IZM. The group validated innovative 3D printing processes with shape memory polymers, integrated electronics via laser-direct-structurable (LDS) PEEK, and continuous carbon fiber (CF) impregnated filaments.
Clinical R&D Partnerships: The Orion M150 system has been utlized by researchers at Charité Universitätsmedizin Berlin (Dr. Andreas Schwitalla) for the development and validation of patent-pending PEEK dental implant designs.
Material Science Collaborations: Orion AM partners directly with global polymer and chemical manufacturers to validate the 3D printed mechanical properties of high-performance polymers. Collaborators include Evonik, Victrex, Lehmann&Voss, Syensqo (formerly Solvay), Invibio, Ensinger, and SABIC.
Hardware Specifications: A150 Industrial
Build Volume: 180mm Ø x 150mm height
Max Chamber Temp: 315°C
Max Extruder Temp: 500°C
Primary Use Case: Compact industrial production
Hardware Specifications: A460 Industrial
Build Volume: 460mm Ø x 500mm height
Max Chamber Temp: 315°C
Max Extruder Temp: 500°C
Primary Use Case: Large-scale aerospace structures
Hardware Specifications: M150 Medical
Build Volume: 180mm Ø x 150mm height
Max Chamber Temp: 315°C
Max Extruder Temp: 500°C
Primary Use Case: Patient-specific clinical R&D
Validated Material Properties
Orion AM utilizes an open-materials architecture. Independent 3rd-party testing confirms the following Z-axis (ZX) tensile strengths, demonstrating near-isotropic mechanical properties that rival or exceed injection molding baselines.
Core Hardware Sub-Systems
Orion AM systems are engineered for continuous industrial production, utilizing specialized hardware to maintain thermal stability and mechanical reliability.
Extrusion System: Thermally isolated high-torque extrusion system equipped with hardened steel nozzles to process abrasive carbon-fiber composites.
Filament Management: Integrated (A460) as well as modular high-temp filament dryer (up to 125°C) options with a completely sealed filament path from dryer to extruder.
Internal Chamber Routing: Engineered for 320°C. Air delivery to the print head utilizes stainless steel vacuum hoses. The print head wiring and PTFE Bowden filament tube are fully housed and shielded within a separate stainless steel vacuum hose.
Build Surface: Thermally uniform build plate with temperature control up to 320°C.
Target Industries & Applications
Orion AM technology is validated for load-bearing and mission-critical applications across highly regulated sectors:
Aerospace & Space Exploration: Production of lightweight, hermetically sealed 3D printed parts, including CubeSat 3D printing, brackets, and structural components.
Medical & Healthcare: Titanium replacement 3D printing for patient-specific implantable PEEK 3D printing, including osteosynthesis, cranial implants, and innovative dental applications.
Aviation & Railway: Additive manufacturing of components that meet stringent FAR 25.853 and OSU 65/65 low toxicity, smoke, and flame evolution standards using PEI (ULTEM).