Think it, Print it, Fly it
Next-generation drones, or UAVs (Unmanned Aerial Vehicles), are transforming various sectors such as surveillance, industrial inspections, precision agriculture, and logistics. Simultaneously, 3D printing has established itself as a pivotal technology for innovating industrial production. It enables the creation of numerous complex components in short timeframes, reducing waste and costs compared to traditional manufacturing methods.
In the UAV context, additive manufacturing represents a paradigm shift. The ability to create complex geometries without mould constraints and with minimal waste makes this technology ideal for a sector that demands agility, precision, and continuous innovation.
Why is additive manufacturing perfect for drone production?
Implementing 3D printing in the serial production of drones offers numerous advantages, impacting engineering, economic, and production aspects:
Weight reduction and performance enhancement:
Through topological optimisation, material can be removed where unnecessary, significantly reducing weight without compromising strength. Less weight translates to greater autonomy, efficiency, and maneuverability, especially when drones must cover long distances or carry sensors.
Complex designs and design freedom:
Additive manufacturing allows for the production of single-component parts, even with organic, lattice, or hollow shapes, difficult to achieve otherwise. This eliminates joints and assemblies, simplifying production and enhancing functionality. Both SLS and MJF technologies enable the production of intricate geometries without the need for supports, increasing design freedom and structural integrity.
Extreme customisation:
Each function requires a different drone, and with 3D printing, supports, landing gear, and sensor housings can be quickly customised to specific needs—even in unique batches. MJF’s high-resolution capabilities allow for exceptional detail and crisp features in custom applications.
Accelerated R&D:
From CAD file to component in a few days. Designers can test, modify, and relaunch versions in record time, drastically reducing time-to-market. MJF’s rapid printing cycles make it ideal for iterative development with consistent surface finish and part accuracy.
Flexible production even in small volumes:
For many drone manufacturers, volumes don't justify molds or equipment. Additive manufacturing—particularly with scalable technologies like SLS and MJF—makes small-scale or on-demand production accessible without sacrificing quality.
Efficiency and sustainability:
3D printing uses only the necessary material. It reduces waste, simplifies logistics, and promotes a leaner, more responsible supply chain. Both SLS and MJF support materials with reduced environmental impact, like bio-based PA11 or CarbonReduced PA2200, helping to align manufacturing with sustainability goals.
Prototal Group’s material portfolio for drones
The Prototal Group offers a wide range of materials tailored for the UAV sector, supporting both SLS and MJF technologies. Notable materials include:
- Hyper-light Carbon: PA12 reinforced with carbon fiber and hollow glass spheres. Excellent strength-to-weight ratio; floatable and lightweight. Ideal for SLS.
- PA2210 Flame Retardant: Flame-retardant nylon for aerospace-grade safety, compliant with UL 94 V-0. Processed with SLS.
- PA2200 CarbonReduced: A sustainable version of the workhorse PA2200, offering full mechanical performance with 45% lower CO₂ impact. Available for SLS and suitable alternatives exist for MJF.
Case Study: CODRONE – Autonomous aerial inspection
The Danish startup CODRONE develops autonomous drones for pilotless inspection and surveillance. In developing their first product, Aluco, traditional methods proved inadequate to meet the requirements for robustness, lightness, and advanced geometry.
With Prototal’s support:
- Lightweight and robust shells were printed using SLS for electronic and sensor enclosures.
- Assemblies were simplified by integrating multiple parts into one structure.
- Rapid iteration and direct transition from prototype to final production were made possible—benefiting from both SLS's large build volume and MJF's fast cycle times for smaller, high-detail parts.
The result?
A 3D-printed drone frame optimised through topology for minimal material use and maximum strength. Manufactured in PA603CF, a composite nylon with carbon fiber, the final part was:
- 50% lighter than aluminum,
- Mechanically stronger and more vibration-resistant,
- Produced faster and at a lower cost than with traditional methods.
Whether using SLS for complex, high-volume parts or MJF for rapid, precision-driven elements, additive manufacturing has become a cornerstone of drone innovation.
Let’s build the future of flight – Together
Do you have an innovative idea for a drone? Are you seeking the right partner to develop lightweight, durable components ready for production? Contact us for a dedicated consultation. Let’s transform your concept into reality with the speed, precision, and reliability of industrial 3D printing—powered by both SLS and MJF.
Strength, Lightness, Versatility – Drones &
Industrial 3D Printing for the Drone Sector
