HP Additive Manufacturing Solutions has established a dedicated global team focused on enabling UAV manufacturers to accelerate design cycles, optimize performance, and scale production.
By leveraging HP’s industry-leading Multi Jet Fusion (MJF) technology, drone companies are now able to 3D print airframes, ducting systems, housings, battery covers, landing gear, and even complete wings, enabling rapid innovation and deployment across diverse sectors.
Next-Generation UAV Engineering
MJF provides UAV manufacturers with an additive production platform capable of meeting the industry’s toughest requirements:
- Lightweight structures that maximize flight efficiency.
- Rapid iteration and customization, reducing the limitations of traditional manufacturing.
- Robust mechanical properties that withstand demanding field operations.
- Scalable production for small-batch prototyping through to large-scale manufacturing.
The technology enables modular designs that can be optimized until the final production stage, giving manufacturers greater freedom to innovate.
UAV Manufacturers Leveraging HP’s Technology
HP’s Additive manufacturing technology has already been adopted by drone makers worldwide, including:
Unusual Machines – Producer of FPV drones under the Rotor Riot brand. The company’s Skylite drone uses MJF-printed TPU propeller covers, providing exceptional shock absorption and near-indestructible resilience for high-impact environments. Watch the video.
Image courtesy of UAV Works
UAV Works (Spain) – Developers of the collapsible Hunter drone, with 96% of its structure 3D printed. Its folding mechanisms are directly integrated into the design, enabling lightweight portability and easy field assembly. Read more >>
NECO (Texas) – Creators of a rapid-deployment reconnaissance UAV with a fully topology-optimized, single-piece 3D printed structure. Entire fleets can be manufactured at scale, with up to 50 drones produced per day on a single printer. Read more >>
Vecros (India) – Makers of the Athera quadcopter, an AI-powered drone capable of autonomous navigation for inspection and surveillance. Its fully 3D printed structural frame integrates airflow optimization, weather protection, and locking mechanisms directly into the design. Read more >>
Data courtesy of Blueflite
Blueflite (USA) – Developer of a last-mile delivery UAS, which reduced overall airframe weight by 25% using HP’s technology. MJF provided repeatable, scalable production while enabling advanced design features such as integrated lattice structures and optimized fuselage geometry. Watch the video.
Conservation-Driven UAV Innovation
One of the most inspiring applications of HP’s additive manufacturing is the Eye Above Project, founded by Robert Miller, which is tackling wildlife poaching and ecosystem preservation in Africa. Watch the video.
The Eye Above UAV is a fully modular, fixed-wing VTOL aircraft with a two-meter wingspan, built with a PA-12 skeleton reinforced with internal carbon fiber supports. Over 90% of the airframe is 3D printed using MJF, with a complex lattice structure developed over 6,000 design hours.
The platform is designed for:
- Extreme durability in harsh conditions including dust, storms, and wildlife encounters.
- Field repairability, with any section of the modular frame replaceable in under 10 minutes.
- Silent flight, providing stealth capabilities critical for anti-poaching surveillance.
- Payload versatility, including optical, thermal, and radar systems such as synthetic aperture radar for detecting snares.
The drone is currently being deployed in Zambia and South Africa for conservation, surveillance, and community training programs, helping local communities shift from poaching to technical careers in UAV operation and maintenance.
Scalable, Field-Proven UAV Manufacturing
By integrating HP’s Multi Jet Fusion technology into UAV production, manufacturers are achieving breakthroughs in design freedom, structural performance, and production scalability. From FPV drones to VTOL platforms and long-range delivery systems, HP Additive Manufacturing Solutions is driving the next era of UAV production.
