3D Printing for Aerospace & UAV Manufacturing
From flight-ready UAV structures to jigs, fixtures, and cabin components, aerospace teams use Original Prusa fleets to move from design to functional parts in days, on high-temperature engineering polymers, with a transparent, allied supply chain.
Built for aerospace engineering teams
TAA Compliant
Made in EU (NATO Ally) & USA
High-Temp Polymers (PEI / ULTEM, PC, PA-CF)
Open-Source Toolchain
US-Based Support & Fulfillment
Where Aerospace Teams Use Additive Manufacturing
A single desktop fleet replaces slow, costly outsourcing for the everyday parts that keep programs moving, iterating in hours instead of weeks.
UAV Airframes & Structures
Lightweight, complex airframe geometries and load-bearing components printed in carbon-filled and high-temp polymers, iterated rapidly for mission-specific platforms.
Jigs, Fixtures & Tooling
Assembly jigs, drill guides, bonding fixtures, and layup tools produced on demand, eliminating machined-aluminum lead times and tooling spend.
Ducting & Cabin Components
Air ducts, brackets, housings, and interior parts in flame-retardant and aerospace-grade materials, ideal for low-volume and legacy replacement runs.
Propulsion & Test Hardware
Wind-tunnel models, mounting hardware, and test-rig components in engineering polymers that survive elevated temperatures and mechanical load.
Recommended Machines for Aerospace
Purpose-matched to aerospace workloads, from high-temperature super polymers to large-format multi-material tooling.
Prusa Pro HT90
High-Temp Super Polymers: Actively heated chamber for PEI / ULTEM, PC, and carbon-filled materials, the workhorse for flight-ready UAV structures and functional aerospace parts.
Prusa XL+
Large-Format Tooling & Jigs: Multi-material platform with up to 5 toolheads and a large build volume, ideal for layup tools, bonding fixtures, and sizable ducting or brackets.
Prusa CORE One+ (Gen 2)
Enclosed Engineering Workhorse: Fully enclosed and upgradeable for consistent prints in ASA, PC, and nylon, the everyday fleet printer for rapid iteration across an aerospace team.
Aerospace Case Study: Angel Aerial Systems
Longer-Loiter UAVs, Printed In-House
5 Prusa Pro HT90 printers · $20,000 of service-bureau parts avoided in year one · 90 °C chamber held on every print
Aerospace-Grade Materials
Three polymers for flight-ready hardware and the bench behind it, matched to the machines above and supported by the same US-based team. The two special-order grades are scoped with you for quantity, lead time and pricing; PC Blend ships today.
Prusament PEI 1010
Special Order - Prusa Pro HT90 Only
ULTEM-class polyetherimide. Inherently flame-retardant and gamma-resistant, and strong enough to stand in for aluminum alloys on brackets, ducting and functional parts. Made in-house by Prusa Research to a guaranteed ±0.05 mm diameter tolerance, and printed only on the Prusa Pro HT90 and its actively heated 90 °C chamber.
Prusament PC Space Grade Black
Special Order - Not Yet Listed in the US
ESD-safe, ultra-low-outgassing polycarbonate. Developed with space company TRL Space and verified at an ESA-affiliated laboratory: 0.25% total mass loss against a 1% ESA limit, 75 MPa tensile strength and 137.6 °C heat deflection. Prints on a hardened nozzle at 290 °C with a 120 °C bed, and needs no enclosure.
Prusament PC Blend
In Stock - Urban Grey, 900 g NFC Spool
Everyday engineering polycarbonate. The workhorse grade for functional parts that have to take heat and mechanical load, printed on an enclosed Original Prusa machine. Made in-house by Prusa Research and in stock today, so it is the one material on this page you can order directly.
Why Aerospace Teams Choose Prusa Through Printed Solid
| What Aerospace Buyers Need | The Prusa / Printed Solid Approach |
|---|---|
Fleet economics: Prototyping and low-volume production without industrial-system capital cost or per-part service-bureau fees. |
Desktop fleets, not single machines: Scale from one printer to a 5–30 machine cell at a fraction of the cost of legacy industrial platforms, with onboarding and volume pricing. |
Aerospace-grade materials: High-temperature, flame-retardant, and carbon-filled polymers for functional parts. |
Open material system: Run PEI / ULTEM, PC, PA-CF and more on the Pro HT90's heated chamber, with no locked, single-vendor filament ecosystem. |
Supply-chain transparency: Clear hardware origin and no forced cloud dependencies for sensitive programs. |
Allied, open, air-gappable: Designed and built in the EU (a NATO ally) and the USA; open-source toolchain; offline operation available for controlled environments. |
Scoping an Aerospace Fleet?
Send us the part that's slowing you down, or tell us your throughput targets. Our US-based team will map the right machines, materials, and fleet pricing for your program. Safety data sheets, material certifications and origin documentation are available on request.