{"type":"rich","version":"1.0","provider_name":"Transistor","provider_url":"https://transistor.fm","author_name":"Additive Snack","title":"Building Drones at Scale: SLS Production from Low-Volume to High-Rate Manufacturing","html":"<iframe width=\"100%\" height=\"180\" frameborder=\"no\" scrolling=\"no\" seamless src=\"https://share.transistor.fm/e/7825cdf1\"></iframe>","width":"100%","height":180,"duration":2687,"description":"In this episode, host Fabian Alefeld sits down with Nick Classen, General Manager of Northwest Rapid Manufacturing, to explore how the company has grown from supporting early UAV production at Northwest UAV into a leading provider of polymer additive manufacturing (AM) services. Classen shares how Northwest Rapid began using EOS selective laser sintering (SLS) technology in 2008 and continues to operate its original system today.\nThe conversation examines why AM has become a strategic technology for UAV and aerospace applications, enabling lighter-weight components, reduced part counts, complex geometries, and a seamless path from functional prototyping to production. Classen emphasizes the importance of engaging AM experts early in the design process to ensure parts are optimized for manufacturability before release.\n\nThe episode also explores production scaling, with discussions around typical UAV production volumes, market growth driven by defense spending and industry consolidation, and applications ranging from structural brackets and housings to conformal fuel tanks. Classen highlights the role of advanced materials, including Nylon 12, glass-filled polymers, alumide, and flame-retardant materials, as well as the extensive post-processing, coating, testing, and EMI shielding capabilities required to deliver finished production parts. He concludes with insights into Northwest Rapid’s plans to expand into metal AM.\n02:05 The Origins of Northwest Rapid Manufacturing\n03:59 Why AM Makes Sense for UAVs\n06:40 Designing for Additive from the Start\n10:52 Low-Rate vs. High-Rate Production\n12:29 Scaling for Future Market Growth\n14:52 UAV Applications Moving into Production\n16:41 Conformal Fuel Tanks and Structural Components\n20:05 Materials Driving SLS Adoption\n22:27 The Value of Post-Processing\n23:00 Finishing and Certifying Fuel Tanks\n24:16 Understanding EMI Shielding\n24:57 Why More UAV Housings Are Being Printed\n26:07 Growth Trends in the UAV Industry\n28:39...","thumbnail_url":"https://img.transistorcdn.com/27ZYLdyZ8MHWZlxUWh87sIQyB5ttPhwcP3_CmUBDsv0/rs:fill:0:0:1/w:400/h:400/q:60/mb:500000/aHR0cHM6Ly9pbWct/dXBsb2FkLXByb2R1/Y3Rpb24udHJhbnNp/c3Rvci5mbS9zaG93/LzE2NDk0LzE3MDU5/NDgwMjItYXJ0d29y/ay5qcGc.webp","thumbnail_width":300,"thumbnail_height":300}