UAV & UAS
From hand-launched ISR drones to MALE-class platforms, additive lets unmanned aircraft be lighter, more complex, and faster to iterate than any traditional process allows. We focus on UAS Groups 3, 4, and 5.
Groups 3, 4, and 5 UAS make heavy use of high-performance 3D-printed polymers. These materials are selected for light weight, high strength, thermal resistance, and flight-ready durability — and because additive lets airframe geometry change as fast as the mission does.
These larger UAS classes (55–1,320+ lb) carry structural, aerodynamic, and mission-critical loads that hand-launched platforms never see: fuselage frames that must survive catapult launch and arrested recovery, payload bays that hold EO/IR sensors within alignment tolerances, and enclosures that protect avionics through thousands of flight hours.
Group 4 and Group 5 UAS platforms incorporate a large number of 3D-printed polymer parts, especially certified-grade Ultem 9085. We produce lightweight, high-strength polymer airframe components and composite layup tools for Group 2–5 unmanned systems.
Programs we support today.
Fuselage sections, internal frames, and load-bearing brackets in PEI (ULTEM), PEKK (ANTERO), Nylon 12 CF, and other aerospace-grade thermoplastics.
Fairings, covers, radomes, and winglets produced on industrial FDM, SLS, and SLA polymer systems.
Sensor pods, payload bays, and wiring channels for mission-critical avionics and EO/IR systems.
High-end tactical ISR, MALE, and strategic UAS — from catapult-launched Group 3 systems to jet-powered Group 5 platforms.
The capabilities behind your programs.
Aluminum, titanium, and Inconel hardware for thermal, structural, and propulsion applications: production-grade metal additive with HIP and machined finishing.
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High-performance thermoplastic parts in Ultem, PEEK, and Antero on production-grade Stratasys systems.
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End-to-end engineering support: meaningful customer interaction, DFAM, topology optimization, laser scanning, and obsolete-part replication.
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Let’s build hardware.
Send us your drawings, or just sketch on a napkin, and your program timeline. Our engineers will provide a rapid quote and deliver flight-ready parts built to your requirements and delivered on schedule.