---
title: "Intelligent Energy: Hydrogen UAV Parts | AMT PostPro"
description: "Intelligent Energy and Graphite AM printed lightweight UAV casings, then tested PostPro SF100 vapor smoothing for sealing and durability."
canonical: https://amtechnologies.com/resources/case-studies/3d-printed-uav-components/
updated: 2026-10-06
type: case-study
---
Case study · Aerospace & UAV

# Lightweight hydrogen UAV components enhanced through vapor smoothing

Intelligent Energy worked with Graphite Additive Manufacturing to redesign and produce UAV components by 3D printing, then vapor smoothed selected parts on the PostPro SF100 to improve sealing, durability and resistance to the environment.

[Read the full case study (PDF, opens in a new tab)](https://6983077.fs1.hubspotusercontent-na1.net/hubfs/6983077/Website/Case%20Studies/AMT_CS_IE.pdf) [Test your parts](https://amtechnologies.com/test-your-parts/)

Published Jan 27, 2026 Free download, no form

![Hydrogen fuel-cell drone in flight low over open desert at dusk](https://amtechnologies.com/img/resources/cs-intelligent-energy-800.webp)

Photo · An Intelligent Energy hydrogen UAV in flight.

- **Customer**: [Intelligent Energy](https://www.intelligent-energy.com/)
- **With**: [Graphite Additive Manufacturing](https://www.graphite-am.co.uk/)
- **Industry**: Aerospace & UAV
- **Application**: Hydrogen UAV casings
- **Printing**: 3D printing (thin-wall casings)
- **Finishing**: [PostPro SF100](https://amtechnologies.com/products/vapor-smoothing/postpro-sf100/)
- **Published**: Jan 27, 2026

## Lighter casings

Printing lightweight casings with thin-wall, complex geometries cut component weight while keeping the structural integrity that demanding UAV applications need.

## What the SF100 added

To evaluate further improvements, selected UAV components were vapor smoothed on the [PostPro SF100](https://amtechnologies.com/products/vapor-smoothing/postpro-sf100/). The automated finishing step showed clear benefits in surface sealing, durability and resistance to environmental exposure, key factors for UAV systems working in challenging conditions.[1]

## Why it matters

Hydrogen-powered drones place strict demands on component weight, mechanical robustness and long-term reliability. Combining 3D printing with post-processing gave Intelligent Energy a pathway to more efficient, production-ready UAV components.

Result

Surface sealing, durability and resistance to environmental exposure[1]

Full case study

The complete story as a PDF. Free, no form to fill in.

[Download the PDF (opens in a new tab)](https://6983077.fs1.hubspotusercontent-na1.net/hubfs/6983077/Website/Case%20Studies/AMT_CS_IE.pdf)

Related

- [PostPro SF100](https://amtechnologies.com/products/vapor-smoothing/postpro-sf100/)
- [All case studies](https://amtechnologies.com/resources/case-studies/)

Test your parts

## Send us a part. See it smoothed.

We vapor smooth your own parts and send them back with the results. No cost to evaluate · Parts returned · Typical turnaround 2–3 weeks[2]

[Test your parts](https://amtechnologies.com/test-your-parts/) [See the systems](https://amtechnologies.com/products/vapor-smoothing/)

## Sources

1. [Lightweight hydrogen UAV components enhanced through vapor smoothing (Intelligent Energy case study)](https://amtechnologies.com/resources/case-studies/3d-printed-uav-components/) · AMT · Jan 27, 2026
2. [PostPro benchmarking: send us your 3D printed parts](https://benchmarking.amtechnologies.com/) · AMT · read Oct 6, 2026