Sintavia LLC

Davie,  FL 
United States
  • Booth: 2129

Founded in 2012, Sintavia is a provider of metal additive manufacturing solutions primarily for the global Aerospace & Defense (A&D) industry.  The company is committed to quality serial production of metal parts that meet or exceed the exacting standards of the A&D industry, and its customer base includes A&D OEMs and Tier One suppliers.

The company offers on-site metal additive manufacturing via the powder bed fusion process, as well as metrology and metallurgical testing.  By combining production with advanced metrology and metallurgical analyses, Sintavia is able to maintain consistent quality and demonstrate repeatable design metrics.

The company’s state-of-the-art facility in Davie, Florida, is self-sufficient with respect to design, fabrication, quality testing, and post-processing.  Our customers appreciate our commitment to quality and consistency, as well as our technicians’ understanding of the needs of the global A&D market.

Sintavia is AS9100 certified and ISO 17025/ANAB accredited, as well as being ITAR and OASIS registered.

 Press Releases

  • DAVIE, Fla. (March 1, 2017) – Sintavia, LLC, a global leader in independent metal additive manufacturing (“AM”), announced today that it had closed a $15mm round of equity financing from its primary investor, Neff Capital Management LLC. The follow-on investment is in addition to an original $10mm of equity financing by Neff Capital which was announced in July 2015. It is expected that the new investment will be used for additional manufacturing capacity and facility expansion in 2017 and 2018.

    Sintavia's proprietary parameters, processes and quality control procedures make it possible to serially manufacture AM parts and audit quality components for precision industries. 
(Photo: Business Wire

    Established in 2012, Sintavia provides a complete suite of metal AM solutions to OEMs in precision industries worldwide. In particular, the company has built a customer base within the Aerospace & Defense, Oil & Natural Gas, Industrial Turbine, and Automotive industries. “Over the past two years, Sintavia has grown into a leader in the provision of critical metal AM components,” said Brian R. Neff, Managing Partner of Neff Capital Management. “Customers who have worked with Sintavia appreciate the sheer breadth of in-house capabilities — in particular with respect to proprietary material processes, such as the recent developments in F357 Aluminum. Doug has assembled a great team of professionals committed to not only the success of Sintavia, but also of the entire metal AM industry.”

    Added Doug Hedges, President & COO of Sintavia, “It has been refreshing to work with an investor that shares our company’s vision of the future — and future potential — of metal AM. At every stage, Neff Capital has ensured that we have the resources we need to grow and develop the company’s operations. We are excited about the future!”

  • DAVIE, Fla. (February 15, 2017) – Sintavia, LLC, the global independent leader for metal Additive Manufacturing (AM) services, announced today it has broadened its precision scanning and quality control services for critical industries by incorporating high-powered Computed Tomography (CT) scanning capabilities.

    Sintavia utilizes a 225kV and 320kV x-ray source in a single scanning platform. This system allows adjustments to spot size detection, penetrating power, scanning speeds and resolution for different materials used within the AM industry. 
(Photo: Business Wire)

    Sintavia’s Nikon XTH 320 CT scanner offers porosity analysis as well as nondestructive examination of the complex internal networks of AM manufactured components. By adding an industrial CT scanner with multiple kilovolt (kV) X-ray sources, Sintavia is one of very few companies with the capability to confirm quality and ensure the material integrity of AM parts manufactured for aerospace and defense applications.

    “Quality control is the number one reason Sintavia incorporated the CT scanner in our manufacturing process,” said Doug Hedges, Sintavia’s President and COO. “Adding this high-fidelity scanner to our comprehensive manufacturing and testing suite allows us to meet and exceed customer quality specifications.”

    Sintavia’s industrial CT scanner features 225 and 320 kV microfocus X-ray sources that are used depending on the density of material and resolution necessary to analyze internal passages and cooling channels. The 225 kV source is equipped with a reflection target creating a 3 micron spot size which allows Sintavia to generate extremely detailed imaging for aluminum and titanium parts. The 320 kV source is used to penetrate through larger parts or higher density alloys such as nickel alloys and stainless steel with high resolution and magnification.

  • DAVIE, Fla. (January 16, 2016) – Metal AM forerunner, Sintavia, LLC, announced today that it had developed full end-to-end parameters for producing additively manufactured parts in F357 aluminum, as well as other Al-Si alloys, for use in precision manufacturing. Sintavia’s proprietary process for printing F357 aluminum powder was developed specifically to address aerospace and automotive industry needs for components with low density, good processability, and heat conductivity. Though most aluminum alloy parts are manufactured using traditional casting practices, Sintavia is changing the landscape for industries looking to expand beyond traditional manufacturing in foundry-grade aluminum alloys.

    Sintavia’s materials characterization lab uses a wide range of equipment and procedures to perform microscopy, CT scanning, surface analysis, optical spectroscopy, and chemical analysis. (Photo: Business Wire)

    “We are seeing an increased demand for additively manufactured Al-Si parts from both the aerospace and automotive industries,” says Doug Hedges, Sintavia’s President and COO. “With Sintavia’s comprehensive manufacturing capabilities, we have developed processes to make F357 aluminum specimens and quickly test them to demonstrate they meet or exceed these industries’ strict validation parameters.”

    Sintavia’s exclusive processes are designed to meet critical engineering requirements at every step. By establishing a procedure that not only includes pre-build material analysis but also post-production heat treatment and stress relief, the company is able to produce AM components proven to exceed original design strength by up to 125% at net densities of near 100%. Through the performance of strength validation at ambient, elevated, and subzero temperatures, Sintavia is capable of part validation in all critical environments.

    Increasingly, OEMs are demanding — and achieving — reduced cycle times and improved quality from their manufacturing supply chains. Sintavia answers this call for critical manufacturing by leveraging the speed benefits of AM while offering elite powder analysis, post-processing, and mechanical testing on-site. This combination of end-to-end speed, data security, and quality allows Sintavia to offer unprecedented manufacturing services to these important industries.


  • Hot Isostatic Press (HIP)
    Simultaneous application of high temperature and pressure to metals and other materials for a specified amount of time in order to remove porosity and improve their mechanical properties....

  • Hot Isostatic Press (HIP) is the simultaneous application of high temperature and pressure to metals and other materials for a specifi ed amount of time in order to remove porosity and improve their mechanical properties. The temperature, pressure and process time are all precisely controlled to achieve the optimum material properties. The HIP process causes the material to become ”plastic” allowing voids to collapse under the differential pressure. The surfaces of the void’s diffusion bond together to effectively eliminate the defects achieving maximum density, while improving mechanical properties of the components or parts. Depending on the density of the additively manufactured part in an as-built condition, the HIP will eliminate all defects giving a near 100% density.

    The most pronounced benefit of removing printing defects by HIP is that the fatigue properties can be improved since the stress concentrations from the defects are eliminated. The fatigue life can be improved by 10 times by HIPing in the right conditions.

  • Metallurgy and Microscopy
    Sintavia possesses one of the most advanced and sophisticated metallurgical analysis laboratories in the world. Sintavia’s in-house metallurgical laboratory is ISO 17025/ANAB accredited....

  • Sintavia possesses one of the most advanced and sophisticated metallurgical analysis laboratories in the world. The company is capable of performing many highly technical tests and procedures inhouse, allowing it to validate production and analyze specimens to understand the microstructure of each build. Sintavia’s in-house metallurgical laboratory is ISO 17025/ANAB accredited.

    Sintavia uses a Scanning Electron Microscope (SEM) with an Energy Dispersive Spectrum (EDS) - with magnification capabilities to 300,000X for micro analysis and analyzing small areas of interest on samples.

    In addition, Sintavia performs accurate and fast sub-ppm elemental analysis of metals using an Inductively Coupled Plasma (ICP) mass spectrometer. By testing samples pre- and post-build, Sintavia is able to determine the chemical composition of the powder and verify the finished part meets or exceeds industry specifications.

  • Additive Manufacturing
    Sintavia uses a Powder Bed Fusion (PBF) Additive Manufacturing (AM) process to produce production quality metal parts with six high-speed metal printers....

  • Sintavia uses a Powder Bed Fusion (PBF) Additive Manufacturing (AM) process to produce production quality metal parts with six high-speed metal printers. PBF has the ability to produce precise and intricate geometries in a layer-by-layer fashion without the typical tooling needed in conventional subtractive machining processes. A laser or electron beam is used to accurately melt a bed of very fine powder particles (typically varying between 20-80 microns in size), into shapes and geometries that lead to state-of-the-art fully optimized designs.

    Sintavia has developed parameters, processes, and procedures for manufacturing in alloys such as Inconel 718, Inconel 625, Titanium, Aluminum, Stainless Steel and proprietary powders.

    These designs can offer substantial weight savings and performance improvement in advanced component and assembly design. Since the design is controlled directly from a CAD fi le, PBF can produce parts that were at one time impossible to manufacture by conventional processes such as cutting, grinding and drilling. The design is only limited by a designer’s creative abilities. Features such as conformal cooling inserts, functional integration, complex geometries, lattice networks and hollow members are now produced with considerable ease via the PBF process.