Drones on the rise: How 3D printing is changing defence and industry

Drones are no longer just toys for enthusiasts. With the development of additive technologies, they are becoming a key technology for defense, industry, and logistics. The rapid development of drones brings a whole range of new possibilities—from alternatives to traditional fireworks, to inspections of hard-to-reach places, to protecting animals from poachers.

The drone industry is currently one of the most dynamically developing sectors. It is driven by both civilian and defense needs. In industry, drones are used, for example, to inspect wind farms and other hard-to-reach locations. They are also used to monitor large areas, in security systems, and in the entertainment industry—for example, in the form of swarms replacing fireworks. In some US states, drone delivery of food is already being tested for the so-called "last mile."

In the defense industry, the development of drones is being significantly accelerated by the geopolitical situation and ongoing conflicts, which show how quickly needs are changing and how essential adaptability is.

Why 3D printing instead of traditional methods?

Compared to traditional manufacturing methods such as lamination or milling, 3D printing offers a number of advantages that are essential for the development and production of drones. First and foremost, there is no need for expensive molds and tools, which significantly reduces the time and cost of producing prototypes, small and large series. Parts can be designed and manufactured in a single step with integrated functions, reducing the number of joints, weight, and risk of failure. Additive manufacturing also allows for the optimization of geometry.

The availability of skilled labor is equally important. Conventional manufacturing requires manual labor and experienced craftsmen, who are still in short supply on the market, especially in the Czech Republic. Additive technologies largely solve this problem: processes are more automated, less dependent on the human factor, and allow for scaling up production even with a limited number of workers.

The pillars of modern drones

Drones are subject to high demands, particularly in the following areas:

• performance, closely linked to weight reduction,
• isotropic strength, i.e., the same strength in all directions,
• reliability,
• ability to operate in harsh conditions,
• design freedom to respond to ever-changing requirements.

A key performance parameter for drones is their range—a 10–20% increase in efficiency can significantly extend their operational range.

These requirements also place high demands on manufacturing. Additive technologies—such as HP's Multi Jet Fusion (MJF)—offer the advantages of design freedom, rapid prototyping, and mass production.

"For a 2×2-meter drone, we can use HP Multi Jet Fusion technology to print a fuselage with walls about as thick as a few sheets of paper. Yet it is strong enough to withstand the harsh conditions in Africa, where drones monitor animals to prevent poaching."

Gino Balistreri, Unmanned Systems Leader, HP

Modular, mobile, and decentralized production

The defense sector is undergoing a fundamental change in strategy. Whereas the emphasis used to be on centralized production, the trend today is shifting toward regional and distributed production. Additive technologies are ideal for these purposes—they are mobile, flexible, and allow for a high degree of customization. This makes it easy to perform quick repairs in the field or manufacture specific, custom components, such as helmet grilles.

Spare parts for older equipment can also be easily printed without complicated mold preparation, which significantly streamlines the entire maintenance process.

In addition, the modular design of drones allows individual segments to be changed as needed to create devices with different purposes. Therefore, a single drone does not have to fulfill only one role.

With the growing emphasis on decentralized manufacturing, the need to protect manufacturing data is also increasing. Secure manufacturing platforms make it possible to send designs to contract manufacturers without revealing the design itself.

The role of HP and its partners: tailored innovation

HP noticed growing demand for 3D-printed Multi Jet Fusion components for drones several years ago. In response to customer interest, the HP Drones team was formed, bringing together segment managers, application engineers, designers, and marketing specialists. The goal is not only to develop the technology itself, but also to tailor applications to specific market requirements.

"Together with our partners, such as 3Dees Industries, we are working to raise awareness of the possibilities offered by Multi Jet Fusion technology. That is why we consider events such as IDET to be important. Thanks to our partnership, we can also be sure that our printers are operated by well-trained experts."

Gino Balistreri, Unmanned Systems Leader, HP

The flying future

The future of drones will be characterized by increasing autonomy, modularity, and decentralized production. 3D printing will be increasingly used not only in prototyping but also in the production of final components, thanks to its ability to respond quickly to changes and current needs.

Drones reflect the speed of technological progress and prove that additive manufacturing and smart partnerships can drive innovation—not only in laboratories, but also in the real world.