EOS 3D Printing Powers NW Rapid Manufacturing's Drone Production Line

NW Rapid Manufacturing has spent 16 years supplying 3D printed parts to the drone industry, and the pace is accelerating. The Oregon-based company, which spun out of Northwest UAV in 2008, currently operates three industrial EOS SLS systems and is preparing to add two more in order to double capacity in 2027 and double it again in 2028.

SLS as a UAV Workhorse

The company's General Manager Nick Classen says SLS is one of the best technologies on the market for UAV applications. The reasons are practical: parts come off the printer with near-isotropic strength and good tolerances, so they need little post-processing and can go straight to functional use. Weight reduction is the other big factor. Where a mounting fixture once required 20 separate pieces, SLS can produce it as a single consolidated part. On a drone, every gram saved extends flight time and increases payload.

NW Rapid Manufacturing works with a range of nylon powders, including Nylon 12 for prototyping, bio-based Nylon 11, and specialty materials such as carbon fiber-filled, glass fiber-filled, and fire-retardant powders. The carbon and glass fiber options are especially popular for UAV structures because they offer a strong strength-to-weight ratio and stress resistance.

Clients From Defense to Delivery

The company prints engine cowlings, cooling shrouds, fuel tanks, mountings, and airframe components for its parent organization Northwest UAV, which supplies critical parts to drone manufacturers including Insitu, maker of the Boeing ScanEagle. NW Rapid also serves external customers such as Matternet, the FAA-approved drone delivery system developer that has partnered with UPS and the UK's National Health Service. Matternet's Head of Design called NW Rapid the best partner to have by your side when developing a product.

The company also does business with AeroVironment, the U.S. defense contractor specializing in unmanned aerial systems. In addition to printing, NW Rapid offers a full suite of secondary finishing processes: bead blasting, vibratory finishing, hand sanding, vapor smoothing, drilling, painting, dyeing, and electroplating. That in-house capability shortens lead times and keeps quality control internal.

EOS as a Long-Term Partner

What stands out in the interview is the age of NW Rapid's hardware. The company still runs an EOS P 390 built in 2006, acquired in 2008. Classen calls it a workhorse that has delivered consistent results year after year. The planned additions include a dual-laser EOS P 770 for high-throughput production and an INTEGRA P 450 to bridge prototyping and series production. The company plans to expand into metal parts in 2027.