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3. 3D-Printed Drones Companies - Boeing (US) and General Atomics (US) are the Key Players

The 3D-printed Drones market is projected to grow from USD 707 million in 2024 to USD 1,891 million by 2029, at a CAGR of 21.8% from 2024 to 2029.

A 3D-printed drone is a type of unmanned aerial vehicle (UAV) that uses 3D printing in the production of components or structures. This technology, commonly known as additive manufacturing, involves the manufacture of three-dimensional objects from digital models layer by layer. It depends on such materials as polymers, composites and metals for the production of drones. In case there are cases that involve difficultly designed lightweight designs, 3D printing provides an excellent solution for flexibility and performance purposes. This reduces material waste, production time hence improving the development cycle and lowering costs borne by manufacturers. There is still a preference for traditional drone manufacturing techniques like CNC machining and injection molding because of their reliability, scalability and ability to meet rigorous quality requirements. However, these processes generally take more time than 3D printing.

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Major 3D-Printed Drones companies include:

• Boeing (US)
• Parrot Drone SAS (France)
• General Atomics (US)
• AeroVironment, Inc. (US)

Key players in the market for drones made by three-dimensional printing include Boeing (US), Parrot Drone SAS (France), General Atomics (US), AeroVironment, Inc. (US). These firms undertake numerous strategic moves aimed at boosting their competitive position within the marketplace as well as satisfying changing consumer requirements. For example, Aurora Flight Sciences – a subsidiary of Boeing has various manufacturing plants with several internal 3D printers plus effective distribution networks covering North America, Europe, Asia Pacific, and the Rest of the World, significantly contributes to the 3D-printed drones market.

Boeing (US)

Boeing produces commercial airplanes, defense and security systems with it being an aerospace company. The firm has Commercial Airplanes (BCA); Defense, Space & Security (BDS); and Global Services (BGS) segments. In the area of military aircrafts whether manned or unmanned ones, aviation systems development and modification work together with surveillance technologies is what Defense, Space, and Security part of Boeing do.

3D drones are available at Boeing through its branches such as Aurora Flight Sciences and Insitu. Special-purpose unmanned aerial vehicles research and development is done by Aurora flight science which is an America based subsidiary. Unmanned air vehicle systems design, development, production and operation activities are engaged in by Insitu that is situated in the United States also.

General Atomics (US)

General Atomics, established in 1955 as a division of General Dynamics Corporation and acquired by the Blue family in 1986, is a defense and diversified technologies company. The company and its affiliates, namely General Atomics Aeronautical Systems, Inc. (GA-ASI), have operations across five continents. GA-ASI produces unmanned aircraft systems (UAS) and has expertise in electro-optical, radar, signals intelligence, and automated airborne surveillance systems. General Atomics’ international affiliates include General Atomics Europe GmbH, which has facilities in the German states of Saxony and Brandenburg, and Heathgate Resources Pty Ltd in South Australia.

In September 2022, GA-ASI established a new Center of Excellence for Additive Design and Manufacturing (AD&M). The center focuses on the rapid-reaction manufacturing of GA-ASI’s UAS line, utilizing functional and flight-ready additive manufacturing applications, research and development, large-scale tooling, and next-generation flight hardware.

Parrot Drone SAS (France)

Parrot Drone SAS specializes in developing and marketing wireless technology products for consumers and professionals. The company operates in three primary markets: civil drones, connected objects in audio and gardening, and automotive technology, including hands-free communication and infotainment systems. In the civil drones market, Parrot offers quadcopters for recreation and professional use. The company collaborates with CRP Technology (Italy), using Windform materials for Selective Laser Sintering (SLS) additive manufacturing. This collaboration advances the construction of the Bebop 2 leisure drone, employing reinforced composite materials from automotive and wind tunnel testing applications. The company’s use of additive manufacturing demonstrates its commitment to advancing drone technology for consumer and entertainment markets, integrating cutting-edge materials into its products.

AeroVironment, Inc. (US)

AeroVironment, Inc. is pioneer in design and development of unmanned aircraft systems such as Small Unmanned Aircraft Systems (SUAS), Medium Unmanned Aircraft Systems (MUAS), Tactical Missile Systems (TMS), and Others. The compan’s business also divided based on these unmanned aircraft system soluions. It offers a range of products, including long-range tracking antennas, sensors, and missile systems, primarily marketed in the US. AeroVironment uses 3D printing for drones due to the need for lightweight, high-performance components.

In March 2022, the US delivered 100 of the latest model Switchblade drones, followed by an additional 600 AeroVironment Switchblade drones in April, to support the Ukrainian military in countering the Russian invasion. These drones are equipped with armaments designed for anti-tank capabilities.

Skydio, Inc. (US)

Skydio, Inc. specializes in manufacturing drones for battlefield situational awareness, policing, and inspection. These drones operate autonomously using computer vision technology, enabling fully automated missions. The company designs, assembles, and supports its products domestically, with manufacturing facilities in Hayward, CA. It serves a wide range of clients, including the US military, public safety agencies, and utility providers.

Skydio’s drones feature high-powered cameras and AI-powered systems, enabling real-time data capture and enhancing operational efficiency across energy utilities, transportation, public safety, and environmental research sectors. The company utilizes Formlabs Form 3+ stereolithography (SLA printers in its product development phase for prototyping and final design iterations, supporting functional testing and tooling with a variety of materials.

Related Reports:

3D-Printed Drones Market by Component (Frames & Arms, Propellers, Landing Gears, Wing Structures, Mounts & Holders, Enclosures), Type (Fixed-wing, Rotary-wing, Hybrid), Platform, Application, Manufacturing Technique and Region - Global Forecast to 2029

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