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.
Platform classes we serve.
UAS refers to the complete system: the aircraft, the control station, and the links between them. UAV refers to the air vehicle itself. Within that family, three platform classes are driving procurement today, and each has its own airframe architecture, its own materials, and its own part opportunities. We built a dedicated page for each.
Electric and hybrid-electric aircraft that fly the mission with onboard autonomy: cargo, resupply, heavy-lift, and persistent ISR. Motor components, coil cover filters, cooling ducts, and autonomy electronics protection.
Explore AAV Drones
Jet-powered, semi-autonomous uncrewed fighters teaming with crewed aircraft, built for affordable mass. NACA ducts, fuel compartment components, RF shielding, and OML coverings at production rate.
Explore CCA DronesLong-endurance, satellite-linked ISR and strike aircraft flown by pilots from ground stations. Antenna and SATCOM hardware, fuel floors, cooling retrofits, and print-on-demand spares for fielded fleets.
Explore RPAPrograms 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.
ExploreHave a program we can support?
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.