SLS Materials and Additive Manufacturing for Superior UAS Components | NW Rapid Manufacturing
SLS Materials and Additive Manufacturing for Superior UAS Components | NW Rapid Manufacturing
A different kind of 3D printing service | NW Rapid Manufacturing

SLS Materials and Additive Manufacturing for Superior UAS Components

The most common material family used in SLS is Nylon, favored for its balanced mechanical and chemical properties.

1. PA12 Nylon

Nylon 12 is the workhorse of industrial SLS, highly valued for its performance in demanding aerospace and automotive applications and known for its suitability for lightweight SLS airframe design and SLS PA12 structural connectors for military UAVs.

  • High Strength-to-Weight Ratio – Creates lightweight yet robust parts, critical for maximizing flight endurance and minimizing energy consumption.
  • Excellent Durability & Impact Resistance – Parts can withstand high-impact forces without fracturing (ductile failure), which is essential for landing gear, propeller guards, and structural arms.
  • Chemical & Environmental Resistance – Resists various chemicals, oils, and fuels, with very low moisture absorption, ensuring dimensional stability and longevity even in harsh operational environments. Melting point around 325°F and USP Class VI certified for biocompatibility.
  • Fatigue Resistance – Ideal for components that experience repetitive stress, like snap-fit assemblies, hinges, or parts near constantly vibrating engine mounts.

2. Reinforced Nylon Composites

NW Rapid Manufacturing also works with reinforced nylons, which enhance performance in specific areas:

  • Carbon-Fiber-Filled Nylon: Offers the highest strength and rigidity with an excellent strength-to-weight ratio. For high-stress structural components, such as drone arms, motor mounts, and airframes, where stiffness is critical.
  • Glass-Filled Nylon: Provides enhanced stiffness and thermal stability. Used for fixtures, tooling, or parts that undergo sustained loading or exposure to higher temperatures.

The flexibility of SLS materials allows manufacturers to quickly iterate on designs, moving from prototype to end-use part (a critical capability for defense contractors) without the high cost and long lead times of traditional tooling.

Would you like to know more about how NW Rapid Manufacturing's parts are used in high-altitude, long-endurance (HALE) UAVs?

Please don't hesitate to contact us at or request a quote and upload your file today!

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The Selective Laser Sintering Process

SLS is an additive manufacturing technology that uses a high-powered laser (usually a CO2 laser) to fuse tiny particles of powdered material, layer by layer, to create a final part.

  • No Supports Required: The surrounding unsintered powder acts as a natural support for the part during the build. This process allows for the creation of incredibly complex internal geometries, undercuts, and nested parts that would be impossible with traditional molding.
  • Isotropic Strength: SLS parts exhibit nearly uniform mechanical properties in all directions (isotropic), which is a significant advantage over other 3D printing methods, ensuring reliable structural integrity.
3 Easy Steps to SLS Magic!

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Manufacturing Efficiency | Material & Performance Focus

  • Reducing drone component lead time with SLS
  • On-demand manufacturing of UAS parts
  • High-strength nylon for UAV components
  • Fire-retardant SLS material for drone housing
  • Lightweight SLS airframe optimization

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