Lighter drones, more power: MJF technology is changing UAV design

Blueflite is a technology startup focused on the development of autonomous unmanned aerial vehicles (UAVs) for fast, medium-distance shipments. It operates in the last mile delivery segment, which is growing dynamically, and works with global players such as Google and Amazon.

One of the key design requirements in this area is to minimize weight while maintaining strength and structural integrity. This is where the fundamental benefit of industrial 3D printing becomes apparent, allowing the geometry of parts to be optimised in a way that is difficult to achieve with traditional technologies.

The challenge: to reduce weight without losing strength

The development of UAV systems requires constant design modifications and rapid verification of functionality. Every gram of extra weight has a direct impact on the range, battery life and payload capacity of the aircraft. Blueflite was therefore looking for a solution that would not only speed up development, but more importantly optimize the design of the parts in terms of weight.

Traditional manufacturing methods such as machining or injection moulding have proven to be limiting in this context. Mould manufacturing is costly and time-consuming, and it also limits design freedom - making it difficult to achieve the ideal weight-to-strength ratio.

Solution: HP Multi Jet Fusion and Design Optimization

Blueflite therefore deployed HP Multi Jet Fusion technology as its main production platform. Production takes place on an HP Jet Fusion 5600 system with a print area of approximately 380 × 284 × 380 mm, enabling efficient production of functional parts in a single batch.

A key benefit of this technology is the ability to produce complex, topologically optimized geometries that reduce part weight without negatively impacting mechanical properties. Due to the isotropic strength of the material, these parts can be used not only for prototyping but also for real deployment in UAVs.

In practice, these are mainly airframe structural parts, electronics covers or aerodynamic elements where the combination of low weight and strength is essential.

PA12 material: stable properties in real operation

The HP 3D High Reusability PA12 material used provides a very good strength-to-weight ratio, which is crucial for aerospace applications. Thanks to its low hygroscopicity, the material maintains stable properties even in variable conditions, which is important when operating UAVs in different environments.

At the same time, it offers sufficient toughness and resistance to mechanical loads, making it suitable not only for testing but also for end-use components.

Surface treatment and aerodynamics

Further optimization is done by chemical surface smoothing. This process closes the micropores of the material and improves its homogeneity. The result is not only greater resistance to external influences, but also better aerodynamic properties, which again contribute to flight efficiency.

Why MJF also makes sense compared to other technologies

Compared to conventional manufacturing , MJF allows instant design modifications without the need for mould making. This significantly speeds up development and also opens up room for weight optimization.

Compared to other 3D printing technologies, MJF excels above all in consistency of mechanical properties and surface quality. As a result, parts can be produced that meet demanding requirements for both functionality and repeatability - which is essential for aerospace applications.

Measurable benefits: lighter parts, higher performance

The deployment of HP Multi Jet Fusion technology has delivered tangible results for Blueflite. Design iterations run in units of cycles in a short period of time, and print job preparation takes only minutes.

But the most important benefit is the ability to reduce the weight of selected components by up to 25% without compromising strength or functionality. This translates directly into improved UAV performance - longer range, longer endurance or higher payload capacity.

"Blueflite is one of the pioneers, but also leaders, in the field of last mile delivery, which is experiencing a major boom. The use of our MJF technology has allowed us to optimize the design of individual parts to reduce weight while maintaining the structural integrity of the aircraft. This has made it possible to increase range, flight time or cargo weight, which are key characteristics. We started with about 30 parts and currently have more than 60 on each aircraft."

Petr Bártek, 3D Printing Application Engineer CEE/MEMA, HP

Additive manufacturing as a competitive advantage

The Blueflite case clearly shows that additive manufacturing is not just a prototyping tool today, but a full-fledged manufacturing technology. The ability to optimise the design for weight while maintaining mechanical integrity is a major competitive advantage.

It is this combination that allows companies to develop more efficient, higher performing and scalable products.

Want to reduce the weight of your parts?

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