Horizon validates copper coating durability with passivation testing
April 16, 2025
Horizon Microtechnologies, Rheinstetten, Germany, announced that it has been working to validate the robustness of its micro Additive Manufacturing metal coating.
At the beginning of the extensive testing initiative, Horizon subjected its copper coatings (passivated using a new method) to a series of pragmatic tests meant to emulate a number of environmental stresses about which the industry is concerned. The results of these tests are said to have demonstrated a high level of resilience, reinforcing the viability of Horizon’s technology for demanding applications, including electronics, RF components, and space systems.
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“Taken by themselves, our tests demonstrate that concerns about copper ageing on 3D printed or 3D microfabricated parts are largely unfounded for a large set of use cases when our passivation technology is applied, and they are an extremely encouraging result with a view to long-term stability,” stated Andreas Frölich, CEO at Horizon. “By proactively addressing oxidation and degradation challenges, we are demonstrating that our coatings are well-suited for applications requiring high durability and environmental resistance.”
The testing process
‘Passivation’ is a crucial process for preventing the natural ageing of metals such as copper; without protection, exposure to humidity, oxygen, and extreme temperatures can degrade copper coatings and surfaces, leading to oxidation, loss of conductivity, and in some cases, compromised adhesion to underlying structures. These concerns are especially pronounced in the case of advanced applications where the electrical and structural integrity of metal coatings must be maintained over long periods. While various methods exist to improve copper’s durability — such as the application of metallic overcoats, alloying, or using additional protective films or surface treatments — these solutions are often optimised for specific part geometries or material systems (e.g. printed circuit boards) and are not necessarily effective or easy to implement for the additively manufactured products with complex geometries.
To address this bottleneck, Horizon Microtechnologies developed its own passivation process engineered specifically to protect copper coatings on complex additively manufactured microstructures. Recognising the industry’s concerns regarding the applicability of such coatings in non-controlled environments, the company initiated a series of internal stress tests designed to replicate some of the harshest environmental conditions a coated component might experience. The goal was to determine whether its passivated copper coatings could withstand high temperatures, extreme humidity, and exposure to chemically aggressive conditions, such as atomic oxygen — something that is particularly relevant in space applications.
Results
The results of these tests clearly demonstrated the superior stability of Horizon’s passivated copper coating. Across all tests conducted — including high-temperature exposure, prolonged hot humidity, and air plasma exposure — the passivated copper coating was said to have remained visually and electrically unaffected except for a small colour change during the initial heating; standard reference copper suffered significant degradation under the same conditions. Cold exposure tests were also conducted, where both materials showed no visible changes. These findings highlight the remarkable resilience of Horizon’s coating, reinforcing its potential for demanding industrial and aerospace applications where material stability is critical.
The results are said to indicate that Horizon’s passivation process is highly effective in protecting copper coatings against common ageing mechanisms, positioning the company’s technology as a robust solution for high-performance applications. With additional long-term testing according to industry standard test conditions forthcoming, these early findings offer strong evidence that Horizon’s passivation method provides substantial protection, ensuring the longevity and reliability of its coated micro-AM parts.
With these results, Horizon Microtechnologies aims to continue to refine its processes and expand validation efforts.
