Among the various technologies presented to us as ESA technology Broker for the UK is AMSynchro, a software platform that tracks metal powder genealogy, condition and usage across additive manufacturing.
Designed specifically for aerospace and space sector quality assurance and NetZero goals, the system offers secure on-site data capture and AI-assisted decision-making support for reuse, segregation and compliance.
How It Works
AMSynchro takes measurements from across the powder lifecycle, receipt, testing, conditioning, storage, blending, charging, build usage, recovery and disposal, then associates them with parts, machines and processes to enable full genealogy and auditability.
Modular connectors collect data from existing enterprise systems and shop-floor devices to create data models that align powder attributes, process events and test results. Records are stored to support audit trails and analytical services deliver insights, such as genealogy reconstruction and risk flags, which operate on aggregated metadata, avoiding disclosure of underlying proprietary parameters.
The system captures and timestamps powder movements and state changes and associates lots and batches with builds and the resulting parts to maintain genealogy. AMSynchro also combines laboratory and in‑process measurements into a consistent data model and provides rule-based and AI-assisted decision support for material disposition. User dashboards and APIs deliver quality records, reporting and interoperability.
Applications
Aerospace and space manufacturing that use metal AM could certainly benefit from this system, while powder suppliers and service bureaux can take advantage of end-to-end traceability. Ideal for defence and other high-reliability sectors, AMSynchro could also provide industrial R&D lines with digital qualification datasets for new materials and processes.
Advantages
This technology offers a number of potential advantages, including replacing manual or spreadsheet-based logs with structured records that can be searched and queried, improving audit readiness and reducing clerical effort. The system also increases confidence in powder use through the provision of test data, usage cycles and context, and reducing unnecessary disposal while maintaining quality margins.
The system creates a digital thread across suppliers, builds and parts, facilitating non-conformance investigations and faster root‑cause analysis, while also integrating with existing IT/OT systems.
Find Out More:
With a number of potential space sector applications available for this system, you can find out more about this technology here: https://www.esa-technology-broker.co.uk/technologies/predictive-assurance-for-space-additive-manufacturing-amsynchro
If you would like to explore this technology further for potential applications, please get in touch with us by emailing contactus@esa-technology-broker.co.uk.