Engineering Solutions Across Industries
From CAD to delivery, we turn thermoplastic 3D-printed parts solid or foamed (Foam Additive Manufacturing®) into industrial products, from prototypes to series production.
Lightweight Structures with Graded Monomaterial Foams
Oniro manufactures density-graded thermoplastic foam components for marine structures using Foam Additive Manufacturing® (FAM). We turn already certified thermoplastics into ultra-light foams while printing, enabling structural and buoyant zones in a single part — with fewer assembly steps and a clean supply chain.
Up to 80% weight reduction
FAM transforms standard thermoplastics into ultra-light foams during printing, reducing mass while keeping geometry and function integrated.
Compatible with certified marine polymers
Process ASA, r-PET, PA6, PETG and high-performance polymers such as PEEK and PEI without introducing chemical additive or new materials, avoiding extra certification and supply-chain changes.
Porosity gradient control (voxel-by-voxel)
Density and stiffness can be tuned voxel-by-voxel (0.2–0.9 g/cm³), enabling structural and buoyant zones in the same continuous print.
Monomaterial, graded, fully recyclable
No adhesives or mixed cores: a closed-loop monomaterial structure designed for recycling at end-of-life.
What we build
Production parts and core kits for marine structures, including:
- Interior panels & bulkheads
- Hull cores / sandwich core geometries
- Buoyancy modules
- Protective housings
Lightweight Composite Cores and Monomaterial Sandwich Components
Oniro manufactures density-graded thermoplastic foam cores and lightweight components for aerospace structures using Foam Additive Manufacturing® (FAM). We engineer localized stiffness, thickness and bonding surfaces to match your load cases and manufacturing route delivering repeatable, production-oriented parts from prototype to series supply.
Up to 80% weight reduction
FAM transforms standard thermoplastics into ultra-light foams during printing, reducing mass while keeping geometry and function integrated.
Porosity gradient control (voxel-by-voxel)
Density and stiffness can be tuned voxel-by-voxel (0.2–0.9 g/cm³), enabling structural and buoyant zones in the same continuous print.
Compatible with certified aerospace polymers
Supports aerospace thermoplastics such as PEEK/PAEK (PEEK, PEKK, LM-PAEK), PEI (ULTEM™), PPS and sulfone polymers (PPSU/PSU/PES).
Designed for repeatability and qualification paths
Controlled parameters, defined density windows, and documentation packages to support your validation/qualification workflow.
What we build
Production-ready core kits and lightweight structures, including:
- Sandwich panel cores
- Interior components
- UAV / UAM fairings & enclosures
- Equipment housings & ducts
Lightweight Functional Systems in Recyclable Thermoplastics
Oniro manufactures lightweight thermoplastic components with engineered porosity using Foam Additive Manufacturing® (FAM). We deliver repeatable, project-ready parts where weight reduction, acoustic/thermal function, and customization are required from one-offs to series supply for contract and building projects.
Weight reduction to simplify installation
Lightweight components reduce handling effort and can lower structural load requirements (application-dependent).
Functional porosity: acoustic and thermal performance by design
Porosity and density are engineered to target sound absorption damping and thermal insulation, while maintaining stiffness where needed.
Custom geometry without tooling
Net-shape printing enables freeform surfaces, variable thickness, ribs, and integrated mounting features without molds.
Recyclable thermoplastic
Thermoplastic solutions support circular strategies and simplified end-of-life management (project-dependent).
What we build
Project-ready components for interiors and building systems, including:
- Acoustic panels & baffles
- Lightweight partitions & wall elements
- Furniture cores & structural inserts
- Custom functional elements
Programmable Impact Protection in Thermoplastics
Oniro manufactures impact-absorbing thermoplastic components with engineered, density-graded porosity using Foam Additive Manufacturing® (FAM). We design the internal architecture to meet target energy absorption, thickness, weight, and fit constraints delivering repeatable parts from prototypes to pre-series and production supply.
Higher energy absorption
Density-graded structures can deliver up to +47% energy absorption while keeping weight and thickness under control.
Porosity gradient control (voxel-by-voxel)
Density and stiffness can be tuned voxel-by-voxel (0.2–0.9 g/cm³), enabling structural and buoyant zones in the same continuous print.
Single-material, recyclable architecture
Monomaterial parts reduce assembly complexity (no mixed foams/cores), supporting simpler end-of-life management.
Repeatability for pre-series and production
Controlled process parameters and defined density windows support consistent mechanical response across batches.
What we build
Production-ready protective components and inserts, including:
- Helmet liners
- Body protection pads
- Sports protective inserts
- Footwear insoles & damping inserts
High-Fidelity Replicas for Exhibitions and Accessibility
Oniro delivers full-scale tactile replicas and exhibit-ready models combining high-accuracy 3D scanning and precision additive manufacturing. We support museums, institutions, and cultural projects with repeatable, documented workflows for accessibility programs, touring exhibitions, and conservation-friendly display solutions.
High-accuracy digital capture
3D scanning with sub-millimetric accuracy (project-dependent) to preserve geometry and fine details.
1:1 replicas with high geometric fidelity
Full-scale printing optimized for stability, handling, and display—suitable for tactile interaction and public-facing use.
Exhibit-ready finishing
Post-processing and hand finishing to achieve the required surface quality, color matching, and touch-safe textures.
Accessible experiences at scale
Replicas designed for tactile tours, inclusive education, and multi-site installations while protecting originals.
Structured delivery for institutions
Clear deliverables, documentation, and project coordination aligned to institutional requirements and timelines.
What we build
End-to-end replica production for cultural heritage projects, including:
- 3D scanning & digital model preparation
- Full-scale replicas (1:1) or scaled models
- Post-processing & finishing
- Mounting / handling solutions
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Start a technical review
Share your requirements and files or request CAD design support if you don’t have final drawings yet.
If you don’t have CAD: we can support CAD design DfAM based on sketches, references, or functional requirements.
We reply with: feasibility, lead time, quotation path.
Accepted formats: .STEP/.STP, .IGES/.IGS, .X_T, .STL, .OBJ, .3MF, .PDF, .DWG/.DXF, .JPG/.PNG
