Revolutionize UAV 3D print with HP Multi Jet Fusion

Print times can vary depending on several factors, including the material, part size, and number of parts being printed. That said, the typical turnaround time ranges from 24 to 48 hours.

Absolutely. 3D printed parts are fully compatible with traditionally manufactured components, and it's very common to see hybrid drones that combine both without any issues. In fact, many companies start by printing just one part—often because it’s optimized for additive manufacturing (due to complex geometry or the need to reduce weight), or because it’s an interchangeable component that’s easy to integrate into existing assemblies. Once they experience the benefits of 3D printing—such as design freedom, weight reduction, and faster production cycles—they often expand their use to more parts of the drone.

The most commonly used material depends on the specific application, but a widely adopted choice is HP 3D High Reusability PA 12, enabled by Evonik. This material is popular because it allows for the production of thin, lightweight, and highly durable parts, offering an excellent balance between mechanical performance, dimensional accuracy, and cost-efficiency. Its versatility makes it well-suited for a range of drone components

CAD software like SolidWorks, Creo, Fusion or Siemens NX are typically used for designing custom components. HP Design Services can also help with design challenges.

Yes, absolutely. The ability to carry cameras or payloads depends on the type of drone and the mission it’s designed for. For example:

• Inverto Earth uses drones with HP MJF-printed components to plant mangrove seeds across diverse and challenging environments like Indonesia and the Middle East. Their drones are equipped with custom payload delivery systems that can handle over 60 types of seeds-thanks to the design flexibility and durability of HP MJF parts.
• Blueflite integrates HP MJF-printed parts into its logistics drones, which are designed to carry medical supplies, industrial tools, and other critical payloads. Their drones feature modular payload bays and custom landing gear optimized for performance and weight reduction—both essential for safe and efficient delivery operations.

These examples show that 3D printed drones are not only capable of carrying payloads, but also benefit from lighter structures, faster development cycles, and tailored designs that enhance mission performance.

Yes, carbon fiber and glass fiber materials can be used in drone applications, particularly when high strength-to-weight ratios are required. However, these materials often come with trade-offs: they can restrict design freedom due to manufacturing constraints, increase production costs, and slow down the pace of design iterations.

In contrast, HP Multi Jet Fusion (MJF) technology offers significant advantages for drone development. It enables greater design flexibility, allowing engineers to create complex, lightweight geometries that are difficult—or even impossible—to achieve with traditional composite manufacturing methods. Additionally, HP MJF supports rapid prototyping and short production cycles, which are ideal for iterative design processes and accelerating time-to-market.

Ultimately, the choice depends on the specific performance and production requirements of the drone application, but HP MJF provides a compelling alternative when agility, complexity, and cost-efficiency are key considerations.

With HP Multi Jet Fusion (MJF) technology, drone components can be manufactured with thin wall thicknesses, significantly reducing overall weight without compromising functionality. This level of precision is made possible by HP MJF’s capability to produce highly detailed and dimensionally stable parts. Lightweight components are especially advantageous in drone applications, where every gram matters—directly impacting flight time, maneuverability, and energy efficiency. The capability to produce parts that are both lightweight and reliable makes 3D printing a powerful asset in UAV design and development.

Fused Deposition Modeling (FDM) is a widely used 3D printing method, particularly effective for early-stage prototyping. However, when it comes to functional drone components that must endure real-world conditions, material performance—especially in the Z-axis—can be a limiting factor.

A practical example is Vecros, a drone startup that initially used FDM to prototype parts for its autonomous drone, Athera. As the design matured, they transitioned to HP Multi Jet Fusion to meet the demands for higher dimensional accuracy, better surface finish, and more consistent mechanical properties—key factors for reliable performance in the field.

This shift reflects a broader trend where manufacturers adopt HP Multi Jet Fusion printing technology when moving from prototyping to production, particularly in applications like UAVs where precision, strength, and repeatability are critical.