Design for Scalable Defense Production

Manufacturing Readiness for Defense-Grade Additive Production

Bridge the gap between prototype and repeatable production. Use these resources to align your designs with the Department of Defense’s manufacturing readiness requirements. UAV components often span multiple additive manufacturing technologies depending on geometry, material, and production needs. The resources below are organized by process to help guide design for scalable, production-ready manufacturing.

Additive Manufacturing Technologies for Defense Production

Powder Bed Fusion (SAF, SLS, and MJF)

Powder Bed Fusion: For complex, lightweight structures like housings and ducts that require defense-grade consistency at scale.

• Military UAV Part Diagram (Infographic) identifies common UAV components well-suited for powder bed fusion.
• SLS Design Guide covers design considerations that support accuracy, surface quality, and repeatability.
• SAF Design Guide focuses on designing nylon parts for consistent quality and higher-volume production using high nesting densities.
• MJF Design Guide covers design considerations for producing strong, accurate nylon parts with consistent mechanical properties across builds.

FDM (Fused Deposition Modeling)

FDM: For structural components using aerospace-grade thermoplastics (ULTEM™/Antero™) that must survive demanding thermal and chemical environments.

• FDM Design Guide provides recommendations and guidance on wall thickness, orientation, support strategy, and material selection for production-ready FDM parts.
• Additive Manufacturing Benefits for the Drone Industry explores where FDM and other additive processes deliver the most value across UAV development and production.

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