How Additive Manufacturing is Powering the Next Generation of Drones and Autonomous Vehicles

Tuesday 28th October 2025

Introduction – Manufacturing for the Edge

In defence and autonomous robotic systems, innovation happens at speed. Whether operating in the air, underwater, or across complex terrain, every component counts. For manufacturers of drones, unmanned vehicles and autonomous robotic systems, the ability to move quickly from concept to deployment can define mission success.

Additive Manufacturing (AM) has become a key enabler in this space. By offering design freedom, lightweight strength, and low-volume efficiency, 3D printing allows teams to design, iterate, and field-test parts faster than ever before. From sensor mounts and protective housings to payload interfaces, bespoke frames and brackets, AM gives manufacturers the flexibility to build bespoke components that meet demanding technical and environmental requirements, all without the delay or cost of traditional machining.

In some applications, these systems are designed for high-risk or single-use missions — whether assessing hazardous environments, inspecting unexploded ordnance, or operating in combat zones. In such cases, drones and autonomous vehicles must deliver absolute reliability and precision, but at a low enough cost to make their short operational lifespan viable. Additive Manufacturing makes this balance possible: performance where it matters, cost efficiency where it counts.

For the new generation of autonomous and unmanned systems, from UAVs, VTOL aircraft and interceptor drones, to UGVs, USVs and other ground vehicles, or ROVs and underwater vehicles, Additive Manufacturing isn’t just a prototyping tool. It’s a strategic manufacturing capability that accelerates development, reduces risk, and keeps innovation in-house

Why Additive Manufacturing Fits the Mission

In defence and autonomous robotic systems, innovation happens at speed. Whether operating in the air, underwater, or across complex terrain, every component counts. For For drones and autonomous vehicles designed for defence or hazardous environments, precision and performance are everything. But producing those parts, whether a rugged sensor mount, aerodynamic body panel, or lightweight arm, often requires a balance between proven traditional methods and the flexibility of new technologies.

That’s where Additive Manufacturing fits best: not as a replacement, but as a hybrid complement to conventional production. In many cases, the most effective approach is to combine subtractive and additive methods, using injection moulding for repeatable, high-volume components, and AM for those that parts that demand custom geometry, lightweighting, or rapid change.

For low-volume production or project-specific builds, AM can take the lead - manufacturing complete assemblies, brackets, or enclosures directly, without tooling or external suppliers. This hybrid model gives engineers the freedom to innovate while maintaining the quality, consistency, and performance demanded in defence-grade systems.

Additive Manufacturing transforms long-standing limitations into advantages:

• Speed to Market – AM accelerates development cycles. Teams can move from CAD design to functional parts in hours, not weeks, enabling faster testing, iteration, and deployment. UAV developers using in-house SLS systems have seen over 70% reductions in development time, drastically shortening time to flight.
• Lightweight Strength – Advanced polymers and composites used in SLS, SLA, and FFF allow for structural optimisation, hollow sections, lattice infills, and reduced assemblies, without compromising mechanical performance. The result is stronger, lighter designs that extend range or payload capacity.
• Cost and Flexibility – With no tooling, no minimum order quantities, and minimal waste, AM is ideal for one-offs and low-volume production. Defence and aerospace teams can adapt designs between missions or vehicle variants without the expense of retooling — or even produce disposable, single-mission systems built for short-term use.
• Design Freedom – Integrated fixings, internal routing, and complex geometries can be built directly into the part, removing assembly steps and increasing reliability.

In air, across land and under sea, this hybrid manufacturing approach, traditional processes enhanced by AM, gives teams the agility to design and deliver systems that perform, adapt, and deploy faster than ever before.

Key Application Areas: Built for Function and Field Use

When designing drones and autonomous systems for defence or hazardous operations, every component serves a purpose, from aerodynamic efficiency to equipment integration and field resilience. Additive Manufacturing provides the flexibility to engineer each component precisely to that purpose. Common functional applications include:

• Sensor and camera mounts – printed to exact tolerances to maintain calibration and reduce vibration, with easy adaptation for new payload types or specific requirements.
• Protective housings and covers – engineered to shield electronics, optics, and batteries from heat, moisture, or debris while keeping overall weight to a minimum.
• Grippers, manipulators, and arms – essential for unmanned ground or underwater vehicles that must interact with their environment, whether retrieving samples or handling hazardous materials.
• Internal brackets and structural frames – robust yet lightweight supports that can integrate cable routing or cooling features directly into their design.
• Custom payload interfaces – bespoke mounting systems for cameras, sensors, or other mission-specific payloads, enabling quick reconfiguration in the field.

Because these parts can be printed on demand, with no tooling and minimal setup, design teams can respond to operational feedback instantly, refining and reprinting components within hours. This rapid iteration cycle allows parts to move from prototype to testing faster than traditional manufacturing could ever support.

Case Studies: Innovation in Action

Across Aerospace and Defence sectors, leading drone and UAV developers are already using AM to accelerate innovation and gain an edge.

ION Mobility – 80% SLS Components with Formlabs Fuse 1+ 30W

ION Mobility, a UAV manufacturer focused on defence and logistics, produces around 80% of its drone components in-house using SLS printing. By adopting the Formlabs Fuse 1+ 30W system and Nylon 12 GF Powder, ION reduced development costs by 60% and turnaround times by 70%.

The ability to print strong, lightweight housings and motor mounts without supports allows for complex, load-bearing geometries optimised for flight. Parts that once took weeks are now printed in half a day - empowering engineers to test, revise, and deploy designs at record speed.

Teranova – Precision and Repeatability with Form 4 (SLA)

Urban Air Mobility (UAM) specialist Teranova uses the Formlabs Form 4 for producing multiple aerodynamic, presentation-ready prototypes and functional parts per day.

The company uses Black resin for prototypes, Tough 2000 (with a similar strength and stiffness to ABS plastic) for functional parts that need to hold up to extended use and Rigid 10K resin for moulds. The result is a streamlined R&D process that supports the company’s mission to deliver heavy-lift UAM vehicles capable of carrying up to a tonne of cargo.

Tsalla Aerospace – From Test Model to Production with Markforged

Tsalla Aerospace, a leader in VTOL UAV development, uses the Markforged Mark Two and Onyx material (Nylon with micro Carbon Fibre) with continuous Carbon Fibre reinforcement, to print aerodynamic tail assemblies for wind tunnel testing. AM reduced their lead time from two weeks to two days and cut costs by 80%.

The precision of Markforged’s composite printing allowed Tsalla to print seamless, single-part designs - eliminating fasteners and improving aerodynamic performance. The results were so strong and dimensionally accurate that Tsalla transitioned from experimental prototyping to full production using the same system.

These examples show how AM supports every stage of UAV and autonomous vehicle development, from rapid design iteration and testing to producing flight-ready, end-use components.

Beyond Prototyping: Real-World Deployment

The adoption of AM across the defence and autonomous systems sectors signals a shift from experimentation to implementation. What was once a tool for R&D has become a dependable production technology.

Industrial-grade materials such as Nylon 12 and Onyx deliver the thermal stability, mechanical strength, and dimensional accuracy required for real-world conditions, from heat and vibration to underwater operation. In-field or near-field AM is also emerging as a critical asset, allowing teams to print replacement mounts, covers, or structural components close to the point of use, reducing downtime and logistics costs.

For drones designed to operate, and sometimes be lost, in high-risk environments, the value equation has shifted. Additive Manufacturing enables mission-optimised components that are fast, affordable, and fully fit for purpose. Manufacturers gain flexibility and control; defence teams gain reliability and speed.

Conclusion – Manufacturing Agility for Autonomous Systems

As drones and autonomous vehicles take on ever more complex roles, the way they’re built must evolve just as fast. Additive Manufacturing gives engineers the tools to design, test, and deploy with unprecedented agility, building parts that are lighter, stronger, and more adaptable than ever before.

From reconnaissance drones to underwater robots, remotely operated vehicles and unmanned or uncrewed ground vehicles, AM is redefining what’s possible: mission-ready manufacturing that’s faster, leaner, and always within reach.

Ready to Build Smarter and Faster?

Discover how AM can strengthen your development pipeline - from fast prototyping to end-use production. Whichever form of unmanned or autonomous vehicle you are manufacturing, whether above or below ground or underwater, our team can help identify where 3D printing delivers the greatest advantage.

👉 Talk to our Applications Team to discuss your project or arrange a live demo.