Case Studies Archive

Advancing UAV Performance with DMLS Metal 3D Printing

As UAVs become more sophisticated, manufacturers face increasing pressure to deliver lighter, more efficient, and highly optimized components without compromising strength or reliability. Traditional manufacturing methods often limit the complexity and integration of UAV parts, making it difficult to meet the evolving needs of defense, aerospace, and commercial drone markets.

Advancing Thruster and Rocket Component Manufacturing with DMLS

Thruster and rocket applications demand components that can withstand extreme environments — including high temperatures, pressure variations, and corrosive conditions — all while maintaining performance, reliability, and tight tolerances. i3D MFG® leverages Direct Metal Laser Sintering (DMLS) to meet these challenges with precision-manufactured, fully dense metal parts optimized for aerospace propulsion systems.

Advancing Heat Sink Design Through DMLS

As electronic components continue to increase in power density, the need for effective passive cooling systems becomes more critical. Natural convection — a quiet, low-cost, and low-interference cooling method — often struggles to meet the demands of medium to high power outputs. This case study explores how Direct Metal Laser Sintering (DMLS), an advanced additive manufacturing technology, was used to redesign a traditional extruded LED heat sink to significantly improve thermal performance.