Case Study: SAE Aero Design achieves lightweight UAV success with Sinterit SLS 3D printing

SAE Aero Design - Customer Case Study

SAE Aero Design, a student association from Warsaw University of Technology, faced the challenge of designing a competitive unmanned aerial vehicle for the SAE Aero Design competition. The challenge was to create a structurally sound, very lightweight aircraft capable of carrying a heavy payload without using fiber composites, which are prohibited by the competition rules. They turned to Sinterit and its Lisa X SLS 3D printer to produce the necessary parts.

Sinterit's solution provided the team with the ability to manufacture complex, high-precision geometries that were not achievable with their previous methods. Using SLS technology, they produced a critical, high-stress tail boom mount that was both extremely lightweight and durable. This application of Sinterit's technology was a key factor in the team's success, helping them achieve a third-place finish in the Regular class at one competition and a first-place victory in the Micro class at another.

SAE Aero Design