HP Additive Manufacturing (HP) Multi Jet Fusion (MJF) 3D printing is utilised by Blueflite, a U.S.-based UAV manufacturer, to advance the design and production of logistics drone platforms.
Focused on last-mile logistics, Blueflite develops UAV systems for applications such as medical supply transport and urgent parcel delivery, where payload efficiency, flight endurance, and structural reliability are critical.
A key focus for Blueflite has been the fuselage, where reductions in weight directly influence both range and payload capacity. By adopting HP’s MJF technology, the company has been able to produce lightweight, consolidated structures that maintain the stiffness-to-weight ratio required for demanding logistics operations.
The MJF process builds parts layer by layer in a powder bed, applying fusing and detailing agents at the voxel level. This enables consistent material properties, high resolution, and design flexibility not possible with conventional manufacturing. Features such as internal channels, mounting points, and reinforcement structures can be integrated within a single part, reducing assembly steps and minimizing potential failure points.
Documented results from Blueflite’s fuselage development include:
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Inner Tail Cone
Weight reduction: 25% decrease in fuselage mass, improving UAV performance.
- Design efficiency: Modeling time reduced from weeks to hours, with shell and fill preparation limited to five minutes.
- Manufacturing precision: High-resolution printing delivers parts with a refined surface finish for operational use.
- Adaptability: Rapid iteration and prototyping cycles allow designs to be adjusted quickly for mission-specific requirements.
In addition to technical gains, Blueflite has reported reduced reliance on tooling and simplified supply chains. HP Additive’s role in providing reliable 3D printing systems ensures repeatable part quality and scalability across builds, supporting both prototyping and low-volume production.
The collaboration between HP Additive and Blueflite illustrates how additive manufacturing can be applied to unmanned aerial systems, from early-stage design through to serial production.
