Why Drone Manufacturers Are Turning to 3D Printing
Drone manufacturers face a unique set of challenges, from lengthy prototyping cycles and expensive tooling to designing lightweight components that can withstand demanding operating conditions. Traditional manufacturing methods can make it difficult to produce complex geometries, quickly test new designs, and adapt to changing project requirements.
3D printing offers a more flexible approach. By producing parts directly from digital designs, manufacturers can reduce their reliance on traditional tooling, accelerate design iterations, and create complex, lightweight components without compromising their design intent. Bringing additive manufacturing in-house also gives engineering teams greater control over production timelines, helping them move from concept to functional testing faster.
Swiss drone manufacturer PMRobotics incorporated Formlabs’ Fuse Series selective laser sintering (SLS) technology into their workflow to bring production of functional prototypes, end-use components, and manufacturing aids in-house. As a result, PMRobotics reduced individual part lead times from four days to just one day and reduced the overall time to market by 9 months.
Read more about PMRobotics’ success with 3D printing in drone manufacturing.
What Can You 3D Print When Building a Drone?
From initial design testing to functional, end-use components, additive manufacturing allows drone manufacturers to produce a wide range of parts while reducing the need for traditional tooling. Its ability to create complex geometries and lightweight structures makes it particularly valuable for drone applications.
Some of the most common 3D printing applications for drone manufacturing:
- Functional components: Airframes, wings, fuselage sections, motor mounts, brackets, enclosures, and payload housings. Additive manufacturing allows engineers to optimize part geometry, reduce weight, and consolidate multiple components into a single design.
- Prototypes and test parts: Aerodynamic models, fit-check components, and early design iterations. Engineers can quickly produce and evaluate physical parts, make adjustments, and validate designs before committing to production.
- Manufacturing aids: Custom assembly fixtures, jigs, gauges, and production tooling. These applications help streamline assembly processes, improve consistency, and reduce reliance on traditionally manufactured tooling.
Comparing 3D Printing Technologies
Not all 3D printing technologies are suited for the same drone applications. While some excel at producing detailed prototypes, others are better equipped to manufacture durable, lightweight components or support higher production volumes. Understanding the differences between selective laser sintering (SLS), fused deposition modeling (FDM), selective absorption fusion (SAF), and stereolithography (SLA) helps you select the right process for your design requirements, material needs, and production goals.
| Technology | Key Advantages | Common Drone Applications |
|---|---|---|
| SLS (Selective Laser Sintering) | Durable nylon parts, complex geometries, no support structures | Frames, brackets, motor mounts, functional components |
| FDM (Fused Deposition Modeling) | Engineering-grade thermoplastics, large parts, material versatility | Airframe sections, structural components, fixtures, prototypes |
| SAF (Selective Absorption Fusion) | High throughput, repeatability, scalable production | Production batches of housings, brackets, and functional parts |
| SLA (Stereolithography) | High detail, dimensional accuracy, smooth surface finishes | Aerodynamic prototypes, precision housings, fit-check components |
SLS: Complex, Functional Nylon Parts
Selective laser sintering (SLS) is a 3D printing technology that uses a high-powered laser to fuse powdered polymer material into solid components. Because the surrounding powder supports the parts during printing, SLS eliminates the need for traditional support structures, allowing engineers to produce complex geometries, intricate internal features, and functional components that may be difficult to manufacture with other methods.
For drone manufacturers, SLS is particularly useful for producing lightweight, durable nylon components such as frames, brackets, motor mounts, and protective housings. Its ability to produce multiple parts in a single build also makes it a practical option for rapid prototyping and low-volume production.
Drone manufacturer Lightcraft uses the Formlabs Fuse 1+ 30W and Nylon 12 Tough Powder to produce frames, GPS mounts, motor holders, and protective covers. By switching from FDM to SLS, the company can manufacture complex print-in-place mechanisms and has reduced part turnaround times from weeks to hours.
See more on how SLS technology transformed Lightcraft’s workflow.
FDM: Lightweight Structural Components
Fused deposition modeling (FDM) builds parts layer by layer using thermoplastic materials. With engineering-grade materials like ASA, FDM can produce strong, lightweight components suitable for demanding drone applications, including larger airframe structures, wings, and fuselage sections.
Aurora Flight Sciences used Stratasys Fortus FDM printers and ASA thermoplastic to manufacture the wings and fuselage of its jet-powered UAV. The material provided the strength and stiffness needed while maintaining a low-density structure. By optimizing material placement and eliminating the need for dedicated tooling, the team was able to create customized, lightweight aircraft components and reduce overall build time.
See more on Aurora’s use of FDM technology.
SAF: Scaling Drone Component Production
Selective absorption fusion (SAF) is a powder-bed 3D printing technology designed for high-volume production of durable polymer parts. With consistent part quality and high throughput, SAF helps drone manufacturers scale production while reducing costs and maintaining repeatability.
Bifrost adopted the Stratasys H350 with SAF technology to overcome production limitations with their previous additive manufacturing processes. By making the transition, they achieved six to eight times higher throughput compared to their previous SLS workflow, reduced production costs by 40%, and expanded their capacity to fulfill orders exceeding 1,000 parts.
See more on Bifrost’s use of SAF in drone manufacturing.
SLA: Prototyping
Stereolithography (SLA) uses a laser or other light source to cure liquid resin into solid parts, producing highly detailed components with smooth surface finishes and dimensional accuracy. This makes SLA ideal for drone prototyping, functional testing, and design validation before moving into production.
Skydio, a manufacturer of autonomous drones, uses Formlabs SLA 3D printers to create prototypes that closely resemble final production parts. The company uses Rigid 4000 Resin for strength and heat resistance, Tough 2000 Resin to simulate injection-molded plastics, and Clear Resin to inspect internal wiring.
While Skydio uses FDM for quick fit checks, SLA allows its engineers to more accurately evaluate part fit, finish, and functionality before committing to production. This demonstrates how SLA helps drone manufacturers refine designs and validate performance throughout the development process.
See more on Skydio’s use of SLA technology in drone prototyping.
How to Choose the Right Technology
Choosing the right 3D printing technology depends on your specific drone application. Factors like material strength, part complexity, production volume, and budget all play a role. Knowing your priorities is the first step.
Not sure which technology is right for your project?
Take our 3D Printing Technology Quiz to explore which additive manufacturing solution best aligns with your design and production needs.
Which 3D Printing Technology Fits Your Parts?
Answer five questions and we will tell you which of the five technologies we run is the right match. Start below.
From Prototype to Production with CADimensions
3D printing gives drone manufacturers the flexibility to innovate faster, optimize designs, and streamline manufacturing across the full development cycle. The right technology depends on your application: SLA for precision prototyping, SLS for complex functional components, FDM for large structural parts, SAF for scalable production runs.
At CADimensions, we’re here to help you make that decision with confidence. As a trusted partner for Formlabs and Stratasys 3D printing solutions, we provide the expertise and support to help you find the right fit for your application, from material selection and design optimization to implementation and training.
About Jacquelyn Carbo
Jackie has 8 years of marketing experience, including 5 years in tech marketing. Before joining CADimensions, she primarily worked in the EdTech sector. Over the past year, she has focused on creating content about engineering, 3D printing, and additive manufacturing, helping make complex technical topics accessible and engaging.
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