3D Printed Drones

Accelerate drone development with lightweight, flight-ready drone parts.

ITAR Registered

ISO 9001:2015

Certifications

CAGE Code: 9C1Z8

The Future of Drone Production

As the drone industry expands, engineers are turning to additive manufacturing to overcome challenges that slow innovation and raise costs:

» Avoid delays from long redesign and retooling cycles

» Produce complex or customized drone components at scale

» Enhancing aerodynamics and lightweighting for longer flight times

Endeavor 3D accelerates your drone development by delivering flight-ready prototypes, validated parts, and full-scale production runs. With Multi Jet Fusion, we help you achieve lighter, stronger components.

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Rapid Prototyping

Bridge Production

Full Production

Jigs & Fixtures

Spares & Repairs

ACCELERATE YOUR DRONE DESIGNS

Benefits

Quick Iteration Cycles
Test Aerodynamics Early
Optimize Thrust-to-Weight Ratio

Our Services

3D CAD Modeling
FDM & MJF 3D Printing
Assembly

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BRIDGE PRODUCTION FOR SMALL DRONE BATCHES

Benefits

Validate Drone Parts Before Mass Production
Ensure Consistent Flight Performance
Minimize Tooling Costs

Our Services

Small Batch Production
Design for Additive Manufacturing (DfAM)
Quality Inspection

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FULL-SCALE DRONE PRODUCTION

Benefits

On-Demand Manufacturing
Customized Interal Geometries and Lattice Infills
High-Quality Consistency

Our Services

MJF Production-Grade Parts
Specialized 3D Printing Materials
Automated Post-Processing

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CUSTOM JIGS & FIXTURES FOR DRONE ASSEMBLY

Benefits

Precise Assembly Tools
Ergonomic & Lightweight Designs
Digital Manufacturing Workflow

Our Services

Custom Drone Assembly Fixtures
Part Consolidation
Fit & Function Testing

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ON-DEMAND SPARES & REPAIRS

Benefits

Quick Replacement Parts
Minimized Drone Downtime
Reliable & Repeatable Production

Our Services

3D Scanning for Legacy Drone Parts
Digital Part Storage
Flexible, Chemically Resistant Materials

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Why Use Multi Jet Fusion for Drone Parts?

Lightweight and Impact-Resistant Drone Parts

MJF materials deliver isotropic strength and impact resistance, enabling the repeated use of crash-prone drone components while reducing overall weight.

Lattice structures and engineered infill designs cut weight while preserving stiffness
PA 11 and PA 12 deliver excellent fatigue resistance, while TPU adds vibration damping for sensitive payloads

MJF Design Guidelines →

Dimensional Accuracy and Assembly Integration

With tolerances as tight as ±0.3 mm, MJF enables engineers to design complex assemblies that fit together reliably straight off the printer.

Produces repeatable snap-fit features and living hinges for modular assemblies
Supports multi-part alignment and one-piece builds of complex geometries
Reduces machining and post-processing compared to other AM methods

Design for MJF: Snap Fits →

Reduce Downtime with On-Demand Manufacturing

MJF accelerates spare-part production and reduces reliance on overseas supply chains, keeping fleets mission-ready.

Replacement parts can be produced in days, not weeks
Obsolete or legacy drone parts can be digitally re-created from scans or CAD
Fleet operators can batch-print maintenance kits for standardized repairs

Solving Spare Part Obsolescence →

MJF Materials for Drone Applications

Materials	Key Properties	Drone Benefits	Best Applications
PA 12, PA 12 Smooth, PA 12 White, PA 12 FR, PA 12 Light Grey	High strength, dimensional stability, chemical resistance, and low water absorption. PA 12 FR variant adds flame retardancy.	Excellent balance of rigidity, impact resistance, and stress corrosion resistance for structural parts. PA 12 variants offer aesthetic options (e.g., PA 12 Smooth for better finish and PA 12 White for dyeing).	Frames, arms, housings. PA 12 FR for safety-critical components in production drones.
PA 11	A bio-derived material with high ductility, impact resistance, and flexibility.	Superior elongation at break for shock absorption and better recyclability. PA 11 maintains properties in humid environments.	Flexible joints and vibration-dampening parts. Ideal for prototypes needing iterative testing.
TPU	High elasticity, abrasion/tear resistance, chemical resistance, and flexibility.	Recyclable and reusable powder, absorbs impacts well for crash-resistant parts, and allows for rubber-like components without assembly.	Grips, seals, flexible mounts, and production parts requiring damping or sealing.

Blueflite Used 48 MJF Components to Build Lighter Drone

48 3D-printed parts, including fuselage panels, motor mounts, and landing gear

Achieved 25% weight reduction using PA 12 and TPU M88A

Courtesy: Blueflite

Modeling time was cut from weeks to mere hours, accelerating the development cycle

Quick design iterations and prototyping allowed for flexible part modifications

Stainless Steel 316L

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ISO 9001: 2015 Certified | ITAR Registered | CAGE Code: 9C1Z8

Stainless Steel 316L

A non-magnetic stainless steel 3D printing material with resistance to high temperatures and corrosion.

Technology:

Metal Jet

Category	Description	Max Gross Takeoff Weight	Normal Operating Altitude	Knots Indicted Airspeed	Examples
Group 1	Small UAVs	0-20 lbs	<1,200 ft Above Ground Level	100 kts	AeroVironment WASP III
Group 2	Short-range UAVs	21-55 lbs	<3,500 ft Above Ground Level	<250 kts	BAE Systems Silver Fox
Group 3	Medium UAVs	<1,320 lbs	<18,000 ft Above Mean Sea Level	<250 kts	Leonardo DRS RQ-15 Neptune
Group 4	Large UAVs	>1,320 lbs	<18,000 ft Above Mean Sea Level	Any Airspeed	General Atomics MQ-9 Reaper
Group 5	High Altitude/Long Endurance UAVs	>1,320 lbs	>18,000 ft Above Mean Sea Level	Any Airspeed	Northrop Grumman RQ-4 Global Hawk