3D printing is playing an increasingly important role in drone manufacturing. It enables the production of complex components with minimal material usage. This reduces costs and increases the performance and flexibility of drones.
Technologically, 3D printing is based on various additive manufacturing processes, of which selective laser sintering (SLS), fused deposition modelling (FDM) and stereolithography (SLA) are used particularly frequently for the production of drone components.
Selective laser sintering (SLS)
The SLS process uses powdered materials such as nylon or carbon-fibre-reinforced polymers, which are selectively fused by a laser to create lightweight, aerodynamically optimised components that can withstand stress. This method is the preferred choice for complex structures and functional prototypes, as it allows a high level of detail and at the same time does not require the additional supporting structures that are often necessary with other methods.
Fused Deposition Modelling (FDM)
FDM, on the other hand, is particularly cost-effective and allows the rapid production of prototypes or spare parts made of thermoplastics such as ABS or PLA. The further development of special filaments, including carbon-fibre-reinforced or self-extinguishing plastics, makes this process increasingly attractive for industrial applications.
Stereolithographic process (SLA)
SLA is characterised by its extremely high precision, by curing liquid resin with UV light. This technique is particularly suitable for aerodynamically demanding or fine mechanical components that require a smooth surface.
PartsToGo GmbH from Karlsbad, part of Neck Enterprise and an exhibitor at XPONENTIAL Europe 2025, offers all common printing processes and supports its customers from application validation to series production. This has helped it to become one of the largest 3D printing service providers in Europe in recent years. ‘We see ourselves not only as a service provider, but also as a partner that takes innovation and precision into its own hands with every project. Our goal is to shape the future by delivering solutions that are as creative as they are functional,’ says CEO Tobias Röcker.
Material efficiency
A significant advantage of 3D printing for drone production is material efficiency, as each component can be manufactured with minimal waste. Traditional production methods such as milling or injection moulding often result in significant material loss. Additive manufacturing allows manufacturers to use precisely the required quantities of high-performance materials, which not only conserves resources but also reduces the overall weight of the drone. A lower weight results in increased flight time and optimised energy efficiency, which is particularly important for drones that have to travel long distances or transport heavy payloads.
Protective elements
The 3D-WERK Black Forest GmbH offers protective elements for cameras and propellers in series production using 3D printing technology. ‘Our innovative solutions ensure maximum safety and durability of the drones,’ emphasises CEO Gerhard Duda. 3D printing also makes it possible to manufacture these protective elements with high precision and in large quantities, enabling cost-efficient production and rapid availability.
Customisable
Adaptability is another crucial factor. With the ability to customise drones, components can be precisely tailored to specific requirements. This is particularly relevant for industrial applications such as inspection flights, rescue operations or agriculture, where customised sensor mounts, optimised propeller guards or modular payload systems are in demand. Advanced CAD software enables engineers to develop new designs in no time and transfer them directly to production. This is also where HP, which was also exhibiting at XPONENTIAL Europe 2025, comes in: ‘HP Multi Jet Fusion technology offers many advantages for the production of a wide range of drones, including those with complicated designs,’ explains Raffi Beglarian, EMEA 3D Printing Market Manager. In addition, the thermoplastic polyurethane (TPU) materials available through HP's 3D printing technology are ideal for drone production due to their high durability, making them virtually indestructible even in a crash, as Beglarian added.
Plastic vs. metal
However, the durability and resistance of 3D-printed components to extreme weather conditions or mechanical stress is an issue that concerns the industry. Materials such as plastics reinforced with carbon fibre or Kevlar offer an optimal ratio of weight to stability, but they do not always achieve the strength of conventional metal components. The aerospace and defence industries are therefore increasingly researching hybrid manufacturing methods that combine 3D printing with traditional manufacturing processes to ensure both weight advantages and structural robustness.
However, it is undisputed that both companies and end users are already benefiting from shorter development times, lower costs and increased design freedom as a result of 3D printing. The result is greater diversity in the drone market.
Author: Sonja Buske
