Ultra-light drone design with HP industrial 3D printing.
Watch how HP AM built the HP Concept S VTOL UAV airframe.
This video presents the HP Concept S Drone, a vertical takeoff and landing (VTOL) UAV airframe created to explore how 3D printing can support drone development and production.
In UAV design, every gram influences range, endurance, and payload. HP AM used Multi Jet Fusion technology to develop an airframe that targets foam-like weight while maintaining strength and durability. In a three-month engineering sprint, the team completed multiple iterations, refining fuselage geometry, wing profiles, and the combination of carbon fiber with MJF-printed components.
The result is a VTOL platform with a 1.5 m wingspan, an empty airframe under 500 g, and wings around 180 g, designed for production on an HP Jet Fusion 5600 system. The concept shows how digital manufacturing can support both agile iteration and scalable output for drone programs.
The project culminated in a flight test at the Barcelona Drone Center, demonstrating how MJF can support real UAV applications beyond early-stage prototypes and contribute to airframes prepared for real use cases.
