General Atomics Aeronautical Systems, Inc. (GA-ASI) continues to lead the way in delivering advanced medium-altitude and small unmanned aircraft systems through the use of additive manufacturing—also referred to as 3D printing.
GA-ASI 3D-Printed Airframe
This approach fabricates aircraft parts or components directly from digital models, layer by layer. Recently, GA-ASI successfully built a complete airframe using this method. This large unmanned aerial system (UAS) airframe was entirely constructed using metal additive manufacturing.
The unit, which includes a five-foot subsection shown here, is reportedly one of the largest and most intricate metal laser powder bed fusion 3D-printed structures developed to date.
GA-ASI has committed significant resources to additive design and manufacturing technologies for the development of next-generation UAS. The company’s goal is to offer innovative and cost-efficient solutions ahead of operational demand. This effort was carried out in collaboration with the Department of Defense and industry partner Divergent.
Center of Excellence for Additive Manufacturing
In 2022, GA-ASI launched a new Center of Excellence for Additive Design and Manufacturing (AD&M). The Center is dedicated to rapid-response manufacturing for the company’s UAS line, integrating fully operational and flight-qualified additive manufacturing applications, research and development, large-format tooling, and next-generation flight-ready components.
To certify flight-worthy additive manufacturing applications, GA-ASI has expanded its AM ecosystem. This includes the critical capabilities needed to evolve from prototype-level output (“print right once”) to full-scale production (“print right always”).
The established AM ecosystem has made it possible for GA-ASI to achieve consistent, repeatable, and reliable 3D printing for production use. This is further supported by controlled internal processes, a specialized applications team, and a structured roadmap for future expansion.
While GA-ASI conducts ongoing production at its AD&M Center of Excellence, the need for fast-turnaround and limited-scale manufacturing has also led to the creation of a robust AM supply chain. This supports the overflow production of complex, operational thermoplastic and metal parts.
GA-ASI estimates that the use of additively manufactured parts on its MQ-9B platform has reduced tooling expenses by more than $2 million and achieved recurring cost savings of over $300,000 per aircraft through the use of approximately 240 AM parts per unit.
The total number of AM applications is growing rapidly, driven by the success of GA-ASI’s established AM ecosystem. To date, more than 10,000 additively manufactured components have been integrated into its aircraft, with the MQ-9B SkyGuardian® and SeaGuardian® models setting the standard for AM integration in the industry.
