Case Study: Digital Aerolus achieves scalable production of rugged autonomous drone components with Fast Radius

Jeff Alholm - Customer Case Study

Digital Aerolus, a maker of rugged autonomous commercial drones, needed an on‑demand manufacturer to move from prototype parts to production of critical components. After initially seeking help for two parts, Digital Aerolus partnered with Fast Radius for end‑to‑end support — from prototyping and design‑for‑manufacturing guidance to multi‑process production — to meet the precision, durability, and performance demands of their Aertos 130IR platform.

Fast Radius implemented a multi‑process solution (injection molding, sheet metal, CNC and production‑grade additive manufacturing) and used advanced materials such as LOCTITE 3D IND405 and PA 12, providing design for manufacturability and repeatable production. Fast Radius produced the plastic and metal BOM for the GCU and components for the Aertos 130IR, delivering 117 parts across 15 materials using six processes and enabling production at scale.

Digital Aerolus

Jeff Alholm

Chief Executive Officer and Co-founder