A UAV program eats airframes. That's development working. Printed frames, wings, and mounts come back in days at prices that let you fly like you mean it: the spare airframe is a file, not a lead time.
Print, fly, break, learn, print again. The revision costs a build plate, and the next airframe carries the fix. Frames, wings, booms, fuselage sections: consumables priced like consumables.
Airframe revisions turn around in days. The design iterates as fast as the flight log fills.
A composite or machined rebuild is a capital event. A reprint is a line item. Fly the test card you actually need, not the one you can afford to lose.
Ten airframes are ten prints, identical. Lose one, print one. The inventory is a folder.
Falcon series, FFF-printed fixed-wing UAVs: holder of the 3D-printed aircraft distance record at 387.6 km over 6 hours 48 minutes (Falcon V3). Fielded, including deliveries to Ukraine.
Tempest, a 55-lb printed airframe under a $100M U.S. Air Force contract: printed in 9 hours, assembled in 36. Printed on a different process (HP powder-bed nylon); cited because the category is proven at the highest-stakes end of the market.
Published results — their numbers, not ours. We build the same classes of parts, locally.
Gimbal brackets, sensor pods, antenna mounts, battery trays, avionics enclosures. Printed to this airframe and this payload, at weights that don't tax the endurance they're there to serve.
Every gram on the airframe is flight time spent before takeoff. Mounts print at the weight the design needs and no more.
Flight controllers, receivers, and sensors ride in housings printed from ESD-safe compounds: ESD-PC, ESD-ABS, ESD-PETG, with surface resistance per the manufacturer's TDS. Protection you can cite, not assume.
EMI-attenuating ABS and PETG with manufacturer-published shielding data, strongest above 1 GHz and tunable by infill. Noise reduction for RF-dense airframes.
Wind-tunnel models, test fixtures, bench jigs, drill guides, shipping cradles. The half of a flight program nobody photographs, and the half that decides the schedule.
Published FDM studies: polycarbonate tunnel models tracking machined-steel results closely enough for development testing, and scale-model shops building in PC-ABS in days what machining delivered in a week or more.
Published engineering results — their numbers, not ours.
Printed in Kansas City on filament from an ISO 9001:2015-certified U.S. manufacturer. For programs where origin is a requirement, not a preference: certificate of conformance and lot documentation available on any order.
Carbon-fiber nylons where stiffness meets weight. ASA for sun and weather. Polycarbonate where impact matters. ESD and EMI compounds where the electronics demand it. Anything bolted or clamped gets metal in the bolt path: heat-set inserts and compression limiters, so preload runs through steel, not creeping polymer.
Prototypes, UAS, ground support equipment, R&D hardware. Not flight-certified parts, not manned aviation, not airworthiness claims: when a part needs a certificate we don't hold, we say so before you order.
Send the file. Weight, price, and lead time come back the same day, most days. Crash it Tuesday; the reprint is already priced.