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.

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Hydrogen fuel-cell drone in flight low over open desert at dusk
PhotoAn Intelligent Energy hydrogen UAV in flight.
Customer
Intelligent Energy
With
Graphite Additive Manufacturing
Industry
Aerospace & UAV
Application
Hydrogen UAV casings
Printing
3D printing (thin-wall casings)
Finishing
PostPro SF100
Published

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. 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.

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.

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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

Test your parts See the systems