Think it, Print it, Fly it – Drones & 3D Printing

Think it, Print it, Fly it – Drones & 3D Printing

Stronger, Lighter, Faster – Drones & 3D Printing

Industrial 3D Printing for the Drone Sector

Next-generation drones, or UAVs (Unmanned Aerial Vehicles), are profoundly transforming key sectors such as surveillance, industrial inspections, precision agriculture, and logistics. Simultaneously, 3D printing has established itself as a pivotal technology for innovating industrial production. It enables the creation of numerous complex components in short timeframes, reducing waste and costs compared to traditional methods.

In the UAV context, additive manufacturing represents a paradigm shift for producers. The ability to create complex geometries without mold constraints and with minimal waste makes this technology ideal for a sector that demands agility, precision, and continuous innovation.

Why is Additive Manufacturing Perfect for Drone Production?

Implementing 3D printing in the serial production of drones offers numerous advantages, impacting engineering, economic, and production aspects:

  • Weight Reduction and Performance Enhancement: Through topological optimization, material can be removed where unnecessary, significantly reducing weight without compromising strength. Less weight translates to greater autonomy, efficiency, and maneuverability, especially when drones must cover long distances or carry sensors.
  • Complex Designs and Design Freedom: Additive manufacturing allows for the production of single-component parts, even with organic, lattice, or hollow shapes, difficult to achieve otherwise. This eliminates joints and assemblies, simplifying production and enhancing functionality.
  • Extreme Customization: Each function requires a different drone, and with 3D printing, supports, landing gear, sensor housings can be quickly customized to specific needs, even in unique batches.
  • Accelerated R&D: From CAD file to component in a few days. Designers can test, modify, and relaunch versions in record time, drastically reducing time-to-market.
  • Flexible Production Even in Small Volumes: For many drone manufacturers, volumes don’t justify molds or equipment. Additive manufacturing makes small-scale or on-demand production accessible.
  • Efficiency and Sustainability: 3D printing uses only the necessary material. It reduces waste, simplifies logistics, and promotes a leaner, more responsible supply chain. It’s possible to choose CarbonReduced materials, like PA2200, or bio-based materials, like PA11, for improved sustainability performance.

Why SLS?

Among additive technologies, Selective Laser Sintering (SLS) stands out for quality, precision, and reliability in industrial production and for its extensive material portfolio.

  • Complex Geometries Without Supports: Unfused powder supports the part during printing, allowing for intricate shapes, undercuts, internal channels, and lightweight lattices. Unibody structures with integrated functionalities—cable guides, threaded seats, attachments—can be created in a single step.
  • Extra-Large Printing Volumes: Prototal possesses the technological capacity to produce up to 2,000 units per day thanks to large-format SLS systems (up to 700×380×580 mm). Small-sized units are processed in batches to optimize productivity and ensure uniform quality. Large-sized units can be printed as a single monolithic block.
  • High-Performance Materials: Drones often operate in harsh environments. SLS supports lightweight and durable technical materials, ideal for resisting heat, impacts, vibrations, and humidity.

Prototal Group’s Material Portfolio for Drones

The Prototal Group offers a wide range of materials, but for the drone sector, the following stand out for their specific properties and superior performance:

  • Hyper-light Carbon: A composite material based on polyamide 12 reinforced with carbon fiber and hollow glass spheres, designed for applications requiring an excellent strength-to-weight ratio. Its extremely low density (0.82 g/cm³) not only lightens components but also allows for the creation of floating parts, ideal for nautical applications or amphibious UAVs. With tensile strength (50 MPa) surpassing standard materials like PA2200 and a precise, uniform surface finish, Hyper-light Carbon is processed with high precision on EOS P770 printers, enabling the production of large monolithic components.
  • PA2210 Flame Retardant: Based on PA2200 but enriched with a halogen-free flame-retardant additive, PA2210 FR is the ideal choice for critical environments like aerospace and motorsport. It complies with UL 94 V-0 standards for thicknesses above 2 mm, the FMVSS 302:1991 regulation for US automotive interiors, and holds the Blue Card certification for 3D printing. Its flame-retardant properties are crucial for reducing flame propagation risk, essential for applications where fire safety and chemical resistance are imperative.
  • PA2200 CarbonReduced: PA2200 is the “workhorse” material of SLS 3D printing: a versatile, durable technical nylon certified for biocompatibility and food contact. The CarbonReduced version maintains all known mechanical characteristics of PA2200 but with a 45% lower environmental impact in terms of CO₂. Thanks to its balanced profile and aesthetic surface quality, PA2200 CarbonReduced is perfect for combining sustainability, precision, and functionality.

CODRONE – Autonomous Aerial Inspection

The Danish startup CODRONE develops autonomous drones for pilotless inspection and surveillance. In developing their first product, Aluco, traditional methods proved inadequate to meet requirements for robustness, lightness, and advanced geometry.

Thanks to SLS printing, Prototal Dk assisted CODRONE in creating functional prototypes and transitioning directly to final production, achieving:

  • Lightweight and robust shells for electronics and sensors;
  • Reduction in the number of parts and simplification of assembly;
  • Shorter development times and costs.

“With industrial 3D printing, we can move directly from prototype to final production. The quality and finish of the components provided by Prototal are extremely high.”

— Kristian Husum Laursen, CEO of CODRONE

Lightweight Drone Frame

The project began with a structural optimization phase, where software analyzed the loads, constraints, and operating conditions the frame would face in flight. The result was an organic geometry, reduced to the essentials, using only the material necessary to ensure strength and stability.

For production, SLS technology and a composite material based on polyamide and carbon fiber (PA603CF) were chosen, selected for its advanced mechanical properties, lightness, and thermal resistance.

The result? A frame 50% lighter than its aluminum equivalent, with improved mechanical performance and greater vibration absorption capacity.

 

Thanks to its vertical integration, the Prototal Group supports clients throughout the entire process: from the first prototype to serial production. If volumes increase, production can be transferred to injection molding without changing suppliers.

Additive manufacturing becomes an integral part of the production strategy.

 

 

Discover How We Can Support Your Next UAV Project

Do you have an innovative idea for a drone? Are you seeking the right partner to develop lightweight, durable components ready for production? Contact us for a dedicated consultation. Together, we can transform your concept into reality, with the speed, precision, and reliability of industrial 3D printing.

www.3dprintdrones.com

Prototal Group Prototal Group is the largest provider of 3D printing, tooling, and injection molding services in Northern Europe. With a highly specialized team and advanced technologies, the group supports companies across various sectors, from automotive to medical, offering rapid prototyping and serial production solutions. Prototal Prosilas represents the group’s Italian division, with strong expertise in Selective Laser Sintering (SLS) and the most advanced additive manufacturing technologies.

Voices of Prototal – Noemi Rossi

Voices of Prototal – Noemi Rossi

NEOMI ROSSI

SALES MANAGER – Prototal Prosilas

Voices of Prototal is our space to share experiences, stories, and insights about the world of 3D printing and industrial manufacturing. Through direct testimonials from our colleagues, we aim to tell the story of the industry’s evolution and the value of our work.

“Sailing teaches me discipline and strategy, just like in work: every challenge, whether at sea or in the office, is an opportunity to push beyond limits and reach new milestones.”

Today, we are excited to share the story of Noemi, one of our talented colleagues, who tells us about her background, her work philosophy, and what motivates her on a daily basis. Her testimony reminds us of the importance of passion, continuous improvement, and collaboration in an innovative environment like Prototal.

Introduction and Background:

“My name is Noemi, I’m originally from the Marche region, and after living for many years in Emilia, I decided to join Prototal. My career started in sales, but what motivated me to join Prototal was its innovation and the opportunity to contribute to ambitious projects. I’m thrilled to be part of a team that always strives for excellence and continuous improvement.

I studied Economics and Management in Parma, and I also had the opportunity to experience academics at Saint Francis University in Pennsylvania. My professional path led me to roles as Area Manager and Export Manager in an important company based in Emilia. These experiences gave me a solid understanding of team dynamics and how to handle daily challenges. Today, these experiences influence my work approach: collaboration, efficiency, and the constant search for innovative solutions are the pillars that guide my daily work.”

What gives you energy outside the office?

“Outside of work, sailing is one of my great passions. Sailing teaches me discipline and strategy, and it gives me a sense of freedom that helps me maintain a healthy balance between mind and body. Every regatta is an opportunity to push my limits, just like in work, where every challenge is a chance to grow.”

My Work Philosophy:

“At Prototal, my approach is based on responsibility, proactivity, and the pursuit of innovative solutions. I like to approach every project with a results-oriented mindset, always attentive to quality and efficiency. What motivates me is the opportunity to grow alongside the team, learning from colleagues and daily challenges. Curiosity and continuous improvement are the foundation of my work philosophy, because I believe that every experience enriches the way we approach the future.”

How do you integrate your personality into your work?

“In my work, I try to be authentic, because I believe the best way to collaborate is to be yourself. My sense of humor helps maintain a positive atmosphere, even during the most intense moments. My values of honesty, commitment, and openness influence my approach to work, helping me make decisions that reflect the company’s values. I believe that a mix of professionalism and genuineness contributes to creating an environment where people are motivated, productive, and feel part of a common goal.”

Pride and Challenges:

“The best part of my job at Prototal is definitely the opportunity to work in multicultural teams. Collaboration with people from different cultures enriches every project, bringing new ideas and creative solutions that I wouldn’t have gotten in a homogeneous environment. The moments that make me most proud are when, thanks to teamwork, we achieve ambitious goals and overcome the toughest challenges.

One of the most challenging aspects of my job is managing tight deadlines and high expectations, especially in complex projects that require coordination between multiple teams. The secret to handling these challenges is staying calm, having a clear plan, and working collaboratively. Every difficulty is an opportunity to grow, and that’s what makes my work so stimulating.”

Do you have any work rituals?

“To stay productive, I have some routines that help me start the day off right. Making a to-do list, having a good coffee, and taking a walk to clear my mind are the things that help me stay focused and manage intense days. These small rituals are essential for maintaining a good balance between efficiency and well-being.”

Looking Ahead:

“Looking to the future, my goals are related to both professional growth and improving my work-life balance. I’d like to take on more responsibilities, perhaps by leading more complex projects or cross-functional teams, to contribute even more to Prototal’s success. At the same time, I’m working on finding a healthier balance between career and leisure, to ensure long-lasting well-being.”

My Advice for Those Starting Out:

“My advice to anyone starting out in this field is to always stay curious and open to learning. Every experience is an opportunity to grow, and soft skills like communication and time management are essential. Don’t be afraid to ask for help and learn from more experienced colleagues, as teamwork is key. Finally, always strive to maintain a balance between work and personal life to face challenges with energy and clarity.”

Noemi Rossi – Sales Manager Prototal Prosilas

 

 

📩 Want to know more? Discover our world on www.prosilas.com and follow Prototal Prosilas on LinkedIn to stay updated on the latest innovations!

 

Prototal Group is the largest provider of 3D printing, tooling, and injection molding services in Northern Europe. With a highly specialized team and advanced technologies, the group supports companies from various industries, including automotive and medical, offering rapid prototyping and serial production solutions. Prototal Prosilas is the Italian division of the group, with extensive experience in selective laser sintering (SLS) and advanced additive manufacturing technologies.

Voices of Prototal – Maria Chiara Menco

Voices of Prototal – Maria Chiara Menco

MARIA CHIARA MENCO

PURCHASING OFFICE – Prototal Prosilas

Voices of Prototal is our space to share experiences, stories, and insights into the world of 3D printing and industrial production. Through firsthand accounts from our colleagues, we aim to highlight the evolution of the industry and the value of our work.

“My work philosophy is based on consistency and reliability.”

Professional Background

“My professional journey began with artistic studies at the Art Institute, which immediately introduced me to the world of creativity and design. Later, I worked in the fashion industry in Civitanova Marche, an experience that allowed me to explore my passion for aesthetics and design. However, my path took a different turn when Prototal Prosilas needed new collaborators. Thanks to my father and sister, I became involved in the world of 3D printing and discovered a fascinating universe where creativity and technology meet.”

What Gives You Energy Outside of Work in Prototal?

“Art remains a fundamental part of my life—I draw and paint whenever I can, experimenting with new techniques. Additionally, I love the mountains and nature, which serve as my refuge from daily stress. Hiking with my family is a precious time that helps me recharge and strengthen our bonds.”

How Do You Stay Motivated and What is Your General Work Philosophy?

“For me, teamwork is essential—collaborating and sharing ideas always leads to better results. I am driven by the desire to continuously improve, learn new things, and face every challenge with determination. I firmly believe that consistency and reliability are essential values for anyone who wants to grow professionally.”

Pride and Challenges

“One of the projects I am most proud of is the development of a tracheal stent for a child at the Bambino Gesù Hospital. This intervention demonstrated how our technology can have a concrete impact on people’s lives.

Of course, there are challenges to face, such as different opinions and work methods within the team. However, I believe that communication and mutual respect are key—approaching difficulties with openness and dialogue always leads to professional and personal growth.”

“I love the dynamic nature of my work and the ability to constantly face new challenges. In the company, I have taken on different roles, from the laboratory to the office, and each experience has enriched me. I want to continue on this path, improving my skills and adapting to the industry’s evolution.”

What Advice Would You Give to Someone Starting in This Field?

“Be curious, open to learning, and ready to collaborate. 3D printing is an ever-evolving industry, and those who want to stand out must be willing to step up, learn, and work as a team.”

Maria Chiara Menco – Purchasing Office, Prototal Prosilas

About Prototal Group

Prototal Group is the largest provider of 3D printing, tooling, and injection molding services in Europe. With a highly specialized team and advanced technologies, the group supports companies across various industries, from automotive to medical, offering rapid prototyping and serial production solutions.

Prototal Prosilas represents the Italian division of the group, with extensive expertise in Selective Laser Sintering (SLS) and the most advanced technologies for additive manufacturing.

Voices of Prototal – Silvia Biancucci

Voices of Prototal – Silvia Biancucci

SILVIA BIANCUCCI

ADMINISTRATION MANAGER

“There is nothing we can’t do, we just need to put in the effort and determination.”

What is your professional background?

“My professional journey began in 2001, when I took my first steps as an accountant. Over the years, I’ve been fortunate to grow and develop on the job, learning something valuable from every consultant, colleague, and manager I’ve worked with. Each of them has contributed a piece to the puzzle that defines my skills today. The path that led me to Prototal Group was somewhat unexpected: I was working for an American luxury shoe company when, through a consultant, I came across Prosilas. Joining this group has been incredibly stimulating, and every day I am proud to be part of such a dynamic system.”

What gives you energy outside the office?

“My true passion is traveling. Whether alone, with family, or friends, every trip is an opportunity to discover, grow, and recharge. When I need to relax, I love taking a walk in nature with my dog—it’s my favorite way to clear my mind. I also enjoy reading and listening to podcasts, which keep my mind active, and I practice yoga to stay flexible, both physically and mentally.”

How do you stay motivated, and what is your general work philosophy?

“My approach to work is very similar to my approach to life: I don’t stop in the face of challenges. My motivation lies in knowing that I can contribute to something meaningful, being an active part of a system, and achieving results, no matter how big or small. I am a direct and decisive person, qualities I consider essential for my role. I try to tackle difficulties with practicality, using humor to ease tense moments and finding solutions that work for everyone.”

Pride and challenges

“Working at Prototal excites me, but it comes with its challenges. Transitioning to a new system after the acquisition was a complex moment but also the most stimulating of my career. It’s in challenges that opportunities for growth arise. On the other hand, tight deadlines can be demanding, requiring impeccable management. To handle these, I rely on strict procedures and checklists that help me stay focused and precise.

My goal is to keep improving: standardizing repetitive tasks and dedicating more time to thorough control and verification work. In the short term, I plan to perfect my English with an intensive course abroad, as I firmly believe that learning never ends.”

My advice to beginners?

“Humility, consistency, dedication, and seriousness. And never give up: even when faced with challenges, push forward with determination.”

Silvia Biancucci – Administration Mananger Prototal Prosilas

Voices of Prototal – Michele Paolinelli

Voices of Prototal – Michele Paolinelli

MICHELE PAOLINELLI

STRATEGIC ACCOUNT MANAGER

“Discipline, method, and curiosity are the best tools to face any challenge.”

Michele Paolinelli, Strategic Account Manager di Prototal Prosilas, esperto in progetti innovativi e stampa 3D.

What is your professional background?

“For ten years, I worked as a freelance surveyor, driven by my passion for architecture since high school. It was a job that helped me grow day by day, but at some point, I felt it lacked a stable future. I decided to close my freelance practice and look for a change.
A friend told me about Prosilas, and I was immediately intrigued. After exploring the world of Additive Manufacturing, I had no doubts: this was a new and exciting field with endless applications across diverse industrial sectors. I chose to join this company and never looked back.”

What energizes you outside of work?

“Riding motorcycles is my greatest passion. It’s the only activity that allows me to enter a state of flow: mind and body sync perfectly, and everything flows naturally. Besides motorcycling, I practice powerlifting and crossfit, two disciplines that train me both physically and mentally.

When I want to slow down, I turn to reading, particularly philosophy and non-fiction, as tools to reflect and grow. And I love traveling, especially with Claudia, my wife and life partner, with whom I share unforgettable moments exploring new places and cultures.””

How do you stay motivated, and what is your general work philosophy?

“My method is clear: discipline, precision, and consistency. Every day, I set increasingly ambitious goals because improving myself is the only way to grow. In my current role, empathy plays a key role: building trusting relationships with clients is essential for long-lasting and valuable projects.”

Pride and challenges

“The greatest satisfaction is seeing a happy client, especially when the entire team works cohesively towards a common goal. And when it comes to motorsport projects, it’s the cherry on top!

Of course, there are difficult moments. Technical problems or a client’s financial challenges require a proactive and methodical approach: you must stay calm, identify the root of the issue, and solve it without being overwhelmed by emotions.”

“My goal is clear: I aspire to take on a commercial role where I can lead a team, sharing the experience I’ve gained over the years. I want to manage the most innovative and forward-thinking projects, those that pave the way for the future of our clients and Prototal.”

“My advice for those starting this journey? Never stop being curious. Explore, learn, and continuously improve. Change always starts with you.”

Michele Paolinelli – Strategic Account Manager Prototal Prosilas

Prototal Prosilas has successfully attained its TISAX® LV.3 certification: security and reliability for the automotive sector.

Prototal Prosilas has successfully attained its TISAX® LV.3 certification: security and reliability for the automotive sector.

Prototal Prosilas e la Certificazione TISAX® LV.3

Stampa 3D e sicurezza delle informazioni per il settore automotive

We’re excited to share that Prototal Prosilas has officially obtained the TISAX® (Trusted Information Security Assessment Exchange) LV.3 certification! This achievement underscores our dedication to keeping sensitive information secure and ensuring we meet the highest global standards in data protection—especially in the automotive sector.

Prototal Prosilas ha ottenuto la certificazione TISAX®, un traguardo fondamentale che dimostra il nostro impegno nel garantire i più alti standard di sicurezza delle informazioni per il settore automotive.

What is TISAX® and why does it matter?

TISAX® is an internationally recognized security standard developed by the VDA (Verband der Automobilindustrie) and managed by the ENX Association. It ensures that companies handling confidential projects and sensitive data comply with strict security requirements set by leading automotive manufacturers and suppliers.

A major step forward for Prototal Prosilas

Adding TISAX® to our certifications, alongside ISO 9001, ISO 14001, and IATF 16949, reinforces our position as a trusted partner in the industry. More than just a certification, it reflects our proactive approach to securing data and improving how we manage information.

Why is this important for our customers?

  • Greater reliability and compliance: Automotive clients expect the highest security standards for their data, and TISAX® ensures we meet those expectations.
  • Expanded business opportunities: This certification allows us to work with top-tier companies that demand strict security measures.
  • Stronger data protection: We now have even more rigorous protocols in place to safeguard our clients’ sensitive information.

How TISAX® impacts our operations

Earning this certification meant enhancing security across our organization, including:

  1. Strengthening our protocols for data protection and confidentiality.
  2. Providing continuous security training for our team.
  3. Regularly reviewing and refining our internal processes.
  4. Investing in advanced IT security to counter potential threats.

Looking ahead

This milestone is a testament to the hard work of our entire team—but it’s just the beginning. Maintaining TISAX® standards means constantly evolving, improving, and staying ahead in data security.

We’ll keep investing in innovation and security to ensure our customers get the best and safest solutions possible.

Stay connected with us for more updates on how Prototal Prosilas continues to push the boundaries of security and excellence!