Sculpteo's 3D printing expertise used to develop drone solutions

DRONAVIA DESIGNS cutting-edge safety accessories for professional drones, focusing on lightweight, durable parts made with 3D printing. Its technologies help pilots maintain control and protect their drones in challenging situations, ensuring safe and efficient operations.

The company produces parachute systems, circuit breakers, remote identification, and geocaging devices - critical components for flight safety in complex scenarios. Their integration relies on lightweight technical parts tailored to each drone model, built to withstand shocks and mechanical stress.

Using Multi Jet Fusion (MJF) technology and PA12 material, Sculpteo 3D prints custom structural components for Dronavia: circuit breaker housings, detection enclosures, technical shells. This fast, precise, and reliable production supports compliance with EASA (European Union Aviation Safety Agency) standards.

Additive Manufacturing Delivers Speed and Precision​

"The main challenge in manufacturing parts for onboard drone systems is, naturally, the weight constraint. To preserve the drone’s battery life, it is essential to design parts that are both lightweight - to reduce power consumption - and rigid and durable. The use of high-performance materials is therefore critical," explained Ludovic Pelletey, CEO and R&D manager at Dronavia.

"Today, we manufacture almost all of our parts, whether standard or custom, using additive manufacturing. This includes mounts, covers, and all plastic components designed in-house and integrated into our solutions.

"We primarily use polyamide 12, leveraging MJF (Multi Jet Fusion) and SLS (Selective Laser Sintering) technologies depending on the required finish. MJF is preferred for black parts, while SLS is used for colored components.

Agility Key in Rapidly Evolving Drone Industry

"Lastly, development timelines in the drone industry are extremely short. We must react quickly to every new drone release to rapidly design a perfectly adapted solution. In this regard, the responsiveness offered by 3D printing is a major advantage, enabling us to reduce our time-to-market and keep pace with market evolution significantly," Pelletey added. 

"We need great design freedom and very short lead times to support the launch of each new drone. 3D printing with Sculpteo allows us to go from concept to production in just a few days, while ensuring optimal quality."

Sculpteo CEO Alexandre d’Orsetti says the company sees additive manufacturing "not merely as a means to produce parts but as a catalyst for reimagining design and production".

"It’s about cultivating a manufacturing ecosystem that’s agile, efficient, and innovation-focused. Dronavia’s success shows how embracing 3D printing doesn’t just solve problems, it transforms them into unique strategic advantages," he affirmed. 

For more information: 

www.sculpteo.com

Tel: +44 330 684 5020