HP Additive Manufacturing Enables NDAA-Compliant Drone Production for EIVIE

### Designing for Change US drone manufacturer EIVIE has successfully developed an NDAA-compliant drone using HP's additive manufacturing technology. The company's goal was to create a distinctly different aircraft that prioritizes aerodynamic performance over manufacturing convenience. EIVIE's co-founder and CEO, Damjan Zabovnik, drew inspiration from his experience in cycling, where he set world records and combined his engineering expertise with a deep appreciation for aerodynamics. The EIVIE airframe stands out from the industry's typical angular designs, featuring smooth curves that contribute to its aerodynamic performance. Building an NDAA-compliant platform required replacing major components, including motors and GPS systems, which have compounding effects throughout the aircraft. Zabovnik notes that additive manufacturing allows the company to update the CAD model and print the next iteration without having to build new molds every time, enabling them to keep improving the design instead of waiting for tooling. ### Aerodynamics Without Compromise The EIVIE airframe is a prime example of the advantages of additive manufacturing. Its flowing shape is more than industrial design; every contour contributes to aerodynamic performance. Producing those forms with traditional manufacturing would require significant compromises. Zabovnik emphasizes that the company worked with HP because they wanted to manufacture exactly what they designed, without compromising on aerodynamics. For decades, aircraft were designed around the limits of manufacturing. Additive manufacturing reverses this relationship, allowing engineers to optimize for flight first and production second. This approach enables designers to create complex shapes that would be difficult or impossible to produce with traditional manufacturing methods. ### Engineering for Flight Designing drone components requires careful consideration of multiple factors, including weight, center of gravity, structural strength, and aerodynamics. Optimizing a drone component is not as straightforward as many industrial applications, and additive manufacturing offers a powerful engineering solution. HP supports manufacturers with engineering teams that help optimize parts for additive manufacturing, reducing weight, simplifying assemblies, and improving production efficiency. Zabovnik also highlights the material characteristics of HP's Multi Jet Fusion technology, which provides strength in all directions, similar to metal. This consistency is crucial for structural aircraft components, where strength depends on print orientation in some conventional printing methods. ### Scaling Production While rapid prototyping is often associated with additive manufacturing, both HP and EIVIE see production as the greater opportunity. Additive manufacturing can simplify production, reduce assembly, and lower manufacturing costs. Design optimization plays a key role in these efficiencies, enabling manufacturers to fit more parts into each production run, simplify assembly, and reduce overall costs. Zabovnik believes that additive manufacturing also simplifies scaling a business. Printing is one of the easiest ways to scale effectively, as it requires less tooling, suppliers, and supply chain management compared to traditional manufacturing. This flexibility is essential for companies like EIVIE, which aims to adapt quickly to changing requirements and regulations. ### Building the Next Generation EIVIE manufactures in the United States, with operations in Oregon and California, and has participated in Pendleton's drone accelerator program. Zabovnik believes that advanced manufacturing strengthens the case for building drones domestically, citing the exceptional talent and creativity available in the US. He predicts that aircraft design is entering a new era, where innovative structures and AI-assisted design will accelerate the evolution of drone manufacturing. For EIVIE, additive manufacturing has become more than a faster way to develop prototypes; it has allowed the company to preserve its original design vision while adapting to changing requirements and preparing to scale production in the United States.