During Formnext 2025, Xenia Materials highlighted a collaboration with Italian composite engineering specialist Bercella S.p.A., which produced an aerospace lamination mold using XECARB® 40-C20-3DP, a polycarbonate reinforced with 20% carbon fiber. Fly Mi – EUROAVIA Milano, a student team participating in the IMechE Unmanned Aerial Systems (UAS) Challenge, used the mold to produce the wings of their aircraft.

The XECARB 40-C20-3DP material that Xenia provided to create the wing molds is a carbon-fiber-reinforced polycarbonate that can be fully recycled by shredding and reprocessing the thermoplastic granules after use. Bercella transformed these designs into reality through large-scale 3D printing combined with precision milling and its extensive expertise in composite fabrication.

According to the Fly Mi team, this collaboration was instrumental in producing the lightweight, high-performance wings that contributed to their success at the UAS Challenge.

With a service temperature of 140°C, XECARB 40-C20-3DP shows that polymer-based additive manufacturing materials can meet the demanding conditions of aerospace tooling. The mold produced by Bercella serves as a case study in how lightweight, fiber-reinforced polymers can replace traditional metal tooling, offering faster turnaround times and greater design flexibility without compromising precision or durability.

The collaboration between Bercella and Xenia demonstrates the compatibility of high-performance composite materials and additive manufacturing for aerospace-grade production. By using XECARB 40-C20-3DP in a functional lamination mould, the project underlines how precision engineering and advanced materials can accelerate innovation in composite tooling.

Founded more than 25 years ago, Bercella specializes in the design and production of composite components for aerospace, defense, motorsport, and industrial applications. The company operates across multiple advanced manufacturing processes, including autoclave molding, filament winding, and compression molding, as well as CNC machining, painting, and structural bonding.

Since 2013, Bercella has expanded its capabilities from component industrialization and tooling design to full structural design, allowing it to support customers from the earliest specification stages. Its vertically integrated model enables design, manufacturing, and qualification under one roof, significantly shortening project timelines and reducing costs.

The company’s investment in a materials testing and qualification laboratory in 2018 further strengthened this integrated approach, positioning Bercella among the few European firms capable of managing the entire product lifecycle — from material validation to final part production — internally.

*This article originally appeared on VoxelMatters. Davide Sher is the original author of this piece.