Protolabs Advances Drone Manufacturing With 3D Printing

Digital manufacturing firm Protolabs intends to further integrate advancing technology into its drone production by expanding its Multi Jet Fusion (MJF) 3D printing service.

For this initiative, Protolabs partnered with HP Additive Manufacturing, the 3D printing technology branch of HP. 

3D printing capabilities

Protolabs’ enhanced 3D technology emphasises expanded drone manufacturing, enabling engineering teams to innovate while adhering to strict weight constraints. This process yields thin-walled, nearly translucent components designed for stability and high performance. MJF employs Nylon PA-12, a material featuring impact resistance, durability and a high strength-to-weight ratio tailored for challenging conditions. This makes it ideal for drone applications operating in rugged terrains, extreme temperatures and high winds. 

Protolabs’ expertise has been used across both its US-based, ITAR-registered facilities and its AS9100- and ISO9001-certified 3D printing and machining divisions, which are engineered for high-requirement components.

Suresh Krishna, President and CEO of Protolabs explains the technology: “In this highly competitive industry, where drone developers are innovating at the speed of software, Protolabs is uniquely positioned to help accelerate that pace, delivering flight-ready parts in a matter of days instead of weeks.

“The advances we’re making in Computer Numerical Control (CNC) machining and additive manufacturing are enabling tighter tolerances and lightweighting of parts for drone applications.”

The Minnesota-based company prioritised its manufacturing capabilities with its metal 3D technology in 2020. 

“We see it every day. The designers and engineers we work with in industries like aerospace and medtech are choosing additive manufacturing for complex components in high-requirement applications,” says Greg Thompson, Global Product Manager for 3D Printing at Protolabs.

“These new production capabilities help them optimise their designs to enhance performance, reduce costs and consolidate supply chains — and do so much faster than ever before.”

Protolabs' continued manufacturing operations

Protolabs aims to combine speed and efficiency across the drone industry by expanding its quick-turn CNC machining capabilities. This advancement enables the production of end-use metal and plastic components with tighter tolerances for greater precision, expanded functionality and enhanced cosmetic finishes, ultimately allowing high-performance drones to be manufactured at a rapid pace.

According to Grand View Research, the global drone industry is currently valued at US$69bn and is projected to reach US$140bn over the next ten years. This expansion is propelled by targeted investments in aerospace and defense, as well as the increasing utilisation of commercial drone applications. 

Protolabs' drone customer base has grown more than 90% since 2023. 

Structural changes at Protolabs

Protolabs celebrated its 20-year anniversary with the opening of a 215,000 sq. ft. CNC machining facility. At the time, it marked the company’s eighth centre in the US.

Larry Lukis, Founder of Protolabs, says: “Protolabs has exceeded my wildest dreams. The company was born out of personal frustration that manufacturing parts took months, when it could take days or even minutes.

“There needed to be a way to make it easier and faster for product developers to get prototype parts and accelerate development cycles. Protolabs has achieved that goal and made advanced manufacturing technologies accessible for everyone, from makers to startups to Fortune 500 companies.”