Lightweighting with MJF

The Secret Weapon for Aerospace Drone Engineers

The Weight Problem: Why Every Gram Feels Like a Ton

Imagine this: you’re designing a drone frame, and you’ve nailed the structural integrity. It’s tough, durable, and ready to take on the skies. But there’s one problem—it weighs just enough to turn your sleek drone into a sluggish flying brick. Now you’re stuck in the classic engineering dilemma: how do you cut weight without compromising strength?

For engineers using traditional manufacturing methods, this problem is like trying to solve a Rubik’s cube blindfolded. Machining and injection molding are great for simple geometries, but when you need lightweight, optimized designs—like lattice structures or hollowed-out features—you’re out of luck. And let’s not even talk about how long it takes to retool for every iteration.

This is where Multi-Jet Fusion (MJF) changes the game. With MJF, you’re no longer bound by the limitations of traditional methods. Want a drone frame with intricate lattice structures to shave off 30% of the weight? Done. Need a propeller optimized for aerodynamic efficiency? Easy. MJF gives you the freedom to design for performance, not just for what’s manufacturable.

The Iteration Bottleneck: When “Fast” Isn’t Fast Enough

Every engineer knows the pain of waiting for a prototype. You’ve got the CAD model ready, the design looks solid, and you’re itching to test it. But instead of rapid feedback, you’re stuck in limbo, waiting weeks for a part to arrive—only to find it needs tweaking. Rinse and repeat.

This slow cycle kills momentum. It’s like trying to run a sprint in slow motion. And when you’re working on commercial drones, where innovation moves at the speed of light, you can’t afford to be stuck in the mud.

MJF flips the script. With SICAM’s 48-72 hour turnaround, you can go from CAD model to physical prototype in days. That means you can test, refine, and repeat faster than ever before. Need to tweak the angle of a propeller blade for better thrust? You’ll have the updated part in your hands before your coffee gets cold.

The In-House Capability Gap: You Can’t Do It All Alone

Let’s face it: not every engineering team has access to cutting-edge manufacturing tech. Maybe your shop is great at machining but lacks the tools for advanced additive manufacturing. Or maybe your team is stretched thin, and you don’t have the bandwidth to dive into the nitty-gritty of lightweighting and DfAM (Design for Additive Manufacturing).

Here’s the good news: you don’t have to do it all alone. By partnering with an expert like SICAM, you get access to decades of experience in additive manufacturing. We’re not just here to print parts—we’re here to collaborate. From optimizing your CAD designs for lightweighting to selecting the perfect material for your application, we’ve got your back.

Scaling to Production: From Prototype to Reality

You’ve perfected your prototype. It’s lightweight, efficient, and performs like a dream. But now comes the next challenge: scaling to production. Traditional methods like injection molding require expensive tooling and long lead times, making the transition from prototype to production a logistical nightmare.

With MJF, scaling is seamless. There’s no tooling required, so you can go straight from prototype to production without missing a beat. And thanks to SICAM’s expert processes and proprietary calibration methods, you can trust that every part will meet your exact specifications, whether you’re making 10 units or 10,000.

Why Engineers Are Turning to MJF

So why are aerospace drone engineers flocking to MJF? Because it solves the problems that have been holding them back. It’s fast, precise, and flexible, making it the perfect solution for lightweighting, rapid prototyping, and scaling to production.

But don’t just take our word for it.

Download our Lightweighting with MJF: A Guide for Drone Engineers to see how MJF can transform your design process. This guide is packed with actionable insights, advanced DfAM techniques, and real-world case studies to help you take your drone designs to the next level.

Take the Leap

Engineering is all about solving problems, and MJF is the ultimate problem-solver for aerospace drone design. Whether you’re battling weight constraints, struggling with slow iterations, or looking for a partner to bring your vision to life, MJF has the answers you’ve been searching for.

Ready to level up your designs?

Download the guide and discover how MJF can help you create lighter, faster, and better drones—without the headaches.