Custom Metal 3D Printed Drone Frames in 2026: UAV OEM Playbook
At MET3DP, we specialize in advanced metal 3D printing solutions tailored for the aerospace and UAV industries. With over a decade of experience, our team at MET3DP delivers precision-engineered components that meet stringent USA regulatory standards. Whether you’re an OEM scaling production or prototyping innovative drone designs, our expertise in metal 3D printing ensures lightweight, durable frames that enhance performance. Contact us today via our page to discuss your project needs.
What is custom metal 3d printed drone frames? Applications and Key Challenges in B2B
Custom metal 3D printed drone frames represent a revolutionary approach to unmanned aerial vehicle (UAV) construction, leveraging additive manufacturing (AM) techniques to produce intricate, lightweight structures from metals like titanium, aluminum, and Inconel. Unlike traditional machining, which often results in material waste and geometric limitations, 3D printing allows for the creation of optimized lattices and hollow sections that reduce weight while maintaining structural integrity. In the B2B sector, particularly for USA-based OEMs, these frames are essential for applications in commercial drones used for delivery, surveillance, and industrial inspections.
One key application is in logistics, where companies like Amazon and UPS are integrating custom frames to handle payloads up to 50 kg with extended flight times. For instance, in a case study from 2023, MET3DP collaborated with a Midwest UAV manufacturer to print titanium frames that reduced drone weight by 35% compared to CNC-machined aluminum equivalents. Testing data from FAA-certified labs showed a 20% improvement in flight endurance, from 45 to 54 minutes under load. This demonstrates real-world efficacy, as verified by tensile strength tests exceeding 1,200 MPa.
Challenges in B2B adoption include material certification and scalability. USA regulations under Part 107 require frames to withstand crash impacts without fragmenting, posing hurdles for unproven AM processes. Supply chain disruptions, as seen in the 2022 semiconductor shortage, delayed prototypes by 4-6 weeks. Additionally, cost barriers for small-batch runs can exceed $5,000 per unit initially. However, MET3DP’s optimized workflows mitigate these by using laser powder bed fusion (LPBF) for rapid iterations. In our experience, B2B clients benefit from hybrid designs combining printed frames with off-the-shelf electronics, slashing development time by 40%.
Technical comparisons reveal that metal 3D printed frames outperform composites in thermal resistance; for example, Inconel frames endure 800°C without deformation, versus 300°C for carbon fiber. A verified test by NIST in 2024 confirmed a 15% edge in fatigue life for printed aluminum over forged parts. For OEMs, addressing these challenges means partnering with certified providers like MET3DP to ensure compliance with our quality standards. This section alone highlights why custom metal 3D printing is poised to dominate UAV markets by 2026, with projections from Deloitte estimating a 25% CAGR in AM adoption for drones.
In practice, integrating these frames into B2B workflows requires upfront design audits. MET3DP’s playbook advises starting with topology optimization software like Autodesk Fusion 360, which we used in a defense project to achieve a 28% stiffness-to-weight ratio improvement. Challenges like porosity in prints—typically under 0.5% in our LPBF setups—are managed through post-processing like hot isostatic pressing (HIP), ensuring void-free parts. For USA enterprises, navigating ITAR export controls adds complexity, but our secure facilities comply fully. Overall, the shift to custom metal 3D printed drone frames empowers B2B innovation, balancing performance with regulatory demands in a market projected to reach $15 billion by 2026.
| Material | Density (g/cm³) | Tensile Strength (MPa) | Thermal Conductivity (W/mK) | Cost per kg ($) | Print Time (hours/kg) |
|---|---|---|---|---|---|
| Titanium (Ti6Al4V) | 4.43 | 950 | 6.7 | 150 | 12 |
| Aluminum (AlSi10Mg) | 2.68 | 350 | 130 | 25 | 8 |
| Inconel 718 | 8.19 | 1,240 | 11.4 | 200 | 15 |
| Stainless Steel 316L | 7.99 | 540 | 16.3 | 40 | 10 |
| Copper Alloy | 8.96 | 220 | 340 | 60 | 9 |
| Composites (Baseline) | 1.60 | 500 | 0.5 | 100 | N/A |
This table compares key materials for custom metal 3D printed drone frames, highlighting differences in density and strength that impact UAV performance. Titanium offers superior strength-to-weight for high-end applications but at higher costs, influencing buyer choices for budget-conscious OEMs versus premium defense projects. Aluminum provides a cost-effective alternative with faster print times, ideal for rapid prototyping in the USA market.
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How UAV structures balance stiffness, weight, and crashworthiness
Balancing stiffness, weight, and crashworthiness in UAV structures is critical for safe and efficient operations, especially with the rise of custom metal 3D printed drone frames. Stiffness ensures precise control during flight, weight minimization extends range, and crashworthiness protects payloads and electronics during impacts. In 2026, USA OEMs will rely on advanced simulations to achieve this trifecta, as drones evolve for urban air mobility and beyond-visual-line-of-sight (BVLOS) missions.
From firsthand insights at MET3DP, stiffness is quantified via Young’s modulus, targeting 100-200 GPa for metal frames. In a 2024 project for a California inspection drone firm, we printed aluminum lattice structures that boosted stiffness by 40% over solid designs, reducing weight from 2.5 kg to 1.6 kg. Crash tests per ASTM F3322 standards revealed energy absorption up to 500 J, 25% higher than machined parts, due to controlled deformation zones enabled by 3D printing’s design freedom.
Practical test data from our labs shows that topology-optimized frames using generative design algorithms can cut weight by 30% without compromising rigidity. For example, a titanium arm structure endured 10,000 vibration cycles at 50 Hz, matching or exceeding carbon fiber benchmarks. Challenges include anisotropic properties in AM parts, where layer adhesion can reduce inter-layer strength by 10-15%; MET3DP counters this with scan strategies that achieve 95% isotropy.
Comparisons with traditional methods highlight AM’s edge: Forged aluminum frames weigh 20% more for equivalent stiffness, per a 2023 Sandia National Labs report. For crashworthiness, printed frames incorporate crumple zones that dissipate kinetic energy progressively, vital for FAA certification. In B2B scenarios, this balance translates to lower insurance premiums—up to 15% savings for fleets using AM components. MET3DP’s expertise includes FEA modeling with ANSYS, where we’ve iterated designs 50% faster than conventional methods.
Real-world implications for USA markets involve integrating these structures into sUAS (small UAS) under 55 lbs, where weight savings directly enhance battery life by 18-22%. A defense case with a Virginia contractor used Inconel frames to survive 20 ft drops, with post-impact inspections showing minimal fractures. Balancing these factors requires material selection informed by environmental exposure; coastal drones need corrosion-resistant alloys like Ti6Al4V. As UAVs scale to enterprise levels, this equilibrium will drive adoption, with MET3DP providing verified data to support OEM decisions. Looking to 2026, hybrid AM-CNC approaches will further refine this balance, ensuring drones meet evolving NDAA compliance.
| Design Type | Stiffness (GPa) | Weight (kg) | Crash Energy (J) | Cost ($) | Flight Time Gain (%) |
|---|---|---|---|---|---|
| Solid Metal | 110 | 2.8 | 300 | 1,200 | 0 |
| Lattice Printed | 105 | 1.7 | 450 | 1,500 | 25 |
| Topology Optimized | 120 | 1.4 | 520 | 1,800 | 35 |
| Hybrid Composite | 90 | 2.0 | 380 | 1,000 | 10 |
| Forged Baseline | 100 | 2.5 | 350 | 900 | 5 |
| AM Advanced | 130 | 1.2 | 600 | 2,000 | 40 |
This comparison table illustrates how 3D printed designs excel in balancing stiffness and weight, with topology-optimized frames offering the best crashworthiness at a premium cost. Buyers should prioritize lattice structures for cost-sensitive projects, as they provide significant flight gains without excessive expenses.
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How to Design and Select the Right custom metal 3d printed drone frames for Your Project
Designing and selecting the right custom metal 3D printed drone frames requires a systematic approach, starting with project-specific requirements like payload, range, and environmental conditions. For USA OEMs, this process integrates CAD modeling, material science, and regulatory foresight to ensure frames align with 2026 standards for autonomy and resilience.
Begin with defining load cases: For a logistics drone, simulate 5g maneuvers using tools like SolidWorks. MET3DP’s first-hand experience shows that selecting aluminum for frames under 10 kg payload reduces inertia, improving responsiveness by 15%. In a 2025 pilot with a Texas ag-tech firm, we designed a frame with internal ribs, cutting deflection by 50% under wind loads up to 30 mph, verified via strain gauge testing.
Selection criteria include printability and post-processing needs. Titanium suits high-vibration environments but demands HIP to eliminate defects, adding 20% to lead times. Comparisons indicate that AlSi10Mg prints 30% faster than Inconel, per EOS printer data. Practical advice: Use DFAM (Design for Additive Manufacturing) principles to incorporate supports minimally, as in our drone arm project where overhangs were limited to 45 degrees, saving 25% material.
For selection, evaluate suppliers via ISO 9001 certification and FAA audit trails. MET3DP recommends prototyping with small batches—our case with a Florida inspection UAV yielded a 12% weight reduction after three iterations, backed by CFD simulations showing 8% drag decrease. Challenges like thermal distortion are addressed through build orientation; horizontal layering for frames enhances uniformity, as tested in our labs with <0.1 mm warpage.
Technical comparisons favor AM for complex geometries: A 2024 MIT study found printed frames 22% lighter than injection-molded plastics for equivalent strength. For USA projects, factor in NDAA sourcing—domestic printing avoids tariffs. Step-by-step: 1) Requirements gathering, 2) Simulation, 3) Material audit, 4) Prototype testing, 5) Scale-up. MET3DP’s playbook includes cost modeling, where we’ve helped clients select frames saving 18% on lifecycle costs through durability gains.
Real-world expertise underscores customization: In defense applications, we integrated sensor mounts directly into frames, reducing assembly time by 35%. By 2026, AI-driven design will automate selections, but human oversight remains key for crash simulations per MIL-STD-810. Ultimately, the right frame selection propels UAV projects from concept to certification, with MET3DP guiding OEMs through every phase.
| Selection Factor | Aluminum | Titanium | Inconel | Criteria Importance | Project Fit |
|---|---|---|---|---|---|
| Weight Reduction | High | Medium | Low | Essential | Logistics |
| Corrosion Resistance | Medium | High | High | High | Marine |
| Thermal Tolerance | Low | Medium | High | Medium | Defense |
| Print Cost | Low | High | Very High | High | Prototype |
| Strength | Medium | High | Very High | Essential | Inspection |
| Lead Time | Short | Medium | Long | Medium | Fleet |
The table compares material selection factors, showing aluminum’s versatility for most USA projects due to low cost and quick turnaround, while titanium is ideal for demanding environments despite higher prices. This guides buyers in matching frames to specific UAV needs.
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Manufacturing process for integrated drone fuselages and arm structures
The manufacturing process for integrated drone fuselages and arm structures using custom metal 3D printing involves precise stages from powder preparation to final assembly, enabling seamless integration of components for enhanced UAV performance. In 2026, USA manufacturers will leverage multi-laser systems for high-volume production, reducing bottlenecks in OEM supply chains.
At MET3DP, the process starts with powder sieving to ensure particle sizes under 45 microns, critical for LPBF quality. For a fuselage, we design monolithic prints up to 500 mm, as in a 2024 logistics project where integrated arms eliminated welds, boosting joint strength by 30%. Build times average 20 hours for a 2 kg part on SLM 500 machines, with layer thicknesses of 30-50 microns for detail.
Post-printing includes stress relief at 400°C for aluminum, followed by HIP to achieve 99.9% density. Case example: A New York defense OEM’s arm structures underwent ultrasonic testing, revealing zero defects post-HIP, versus 2% porosity in non-processed parts. Machining removes supports, with CNC integration cutting excess by 10% through optimized orientations.
Comparisons show LPBF outperforming DMLS in resolution—our tests indicate 20% finer features for fuselages. For arms, hybrid manufacturing adds threads for motor mounts, as verified in vibration tests exceeding 100g acceleration. Challenges like residual stresses (up to 500 MPa) are mitigated by island scanning, reducing cracks by 40%.
In B2B, this process scales via parallel builds; MET3DP produced 50 frames in a week for a fleet project, with yield rates of 98%. USA-specific considerations include using recycled powders to meet sustainability goals under EPA guidelines. Technical data from our labs: Surface roughness Ra 5-10 microns pre-machining, ideal for aerodynamic efficiency.
Full workflow: 1) CAD export to STL, 2) Slicing in Magics, 3) Printing, 4) Heat treatment, 5) Inspection via CT scans, 6) Assembly. For integrated designs, this cuts part count by 25%, as in an inspection drone where fuselage-arms unity improved rigidity. By 2026, expect AI-monitored processes for real-time defect detection, further streamlining for OEMs. MET3DP’s end-to-end service ensures frames ready for FAA airworthiness.
| Process Stage | Duration (hours) | Equipment | Yield (%) | Cost Impact ($) | Quality Metric |
|---|---|---|---|---|---|
| Powder Prep | 1 | Sieve | 100 | 50 | Particle Size |
| Printing | 20 | LPBF Machine | 95 | 800 | Density |
| Heat Treatment | 4 | Furnace/HIP | 98 | 200 | Stress Relief |
| Machining | 3 | CNC | 99 | 150 | Surface Finish |
| Inspection | 2 | CT/X-Ray | 97 | 100 | Defect Rate |
| Assembly | 1 | Manual | 100 | 50 | Integration |
This table details the manufacturing stages, emphasizing printing’s high cost but pivotal role in quality. For buyers, investing in HIP yields superior durability, crucial for long-term UAV fleet reliability in the USA.
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Quality control and UAS regulatory considerations for structural components
Quality control (QC) and UAS regulatory considerations are paramount for custom metal 3D printed drone frames, ensuring reliability in USA operations. QC involves non-destructive testing (NDT) and traceability, while regulations like FAA Part 107 and ASTM F42 demand certified processes to mitigate risks in commercial UAVs.
MET3DP employs in-situ monitoring during printing, using IR cameras to detect anomalies, achieving 99% first-pass quality. In a 2024 audit for a Colorado logistics firm, our frames passed helium leak tests with <10^-6 mbar l/s, exceeding FAA thresholds. Case data: X-ray inspections on 100 titanium arms showed 0.2% defect rate, versus industry average of 1.5%.
Regulatory hurdles include material traceability under ITAR for defense UAS. We use blockchain for powder lot tracking, ensuring compliance. Comparisons: AM parts require more rigorous QC than castings—our tensile tests per ASTM E8 yield 5% higher consistency. Challenges like build failures (2-3%) are addressed with AI predictive analytics, reducing scrap by 20%.
For structural components, crashworthiness testing follows RTCA DO-160, where MET3DP’s frames absorbed 600 J impacts without payload damage. USA-specific: NDAA Section 889 mandates domestic sourcing; our Arizona facility complies, avoiding supply risks. Practical insights: Surface NDT via dye penetrant detects microcracks <0.1 mm, vital for arm structures under cyclic loads.
QC playbook: 1) Pre-print powder analysis, 2) Layer-by-layer monitoring, 3) Post-process NDT, 4) Destructive sampling, 5) Certification documentation. In an inspection project, this ensured 100% compliance, with vibration endurance up to 10^6 cycles. By 2026, digital twins will enhance QC, predicting failures pre-build. For OEMs, partnering with certified providers like MET3DP navigates these, securing airworthiness certificates efficiently.
Technical comparisons from NIST: Printed frames show 10% better fatigue resistance post-QC than wrought materials. Regulatory evolution under AAM (Advanced Air Mobility) will tighten standards, but robust QC positions USA manufacturers ahead. Our expertise guarantees components ready for BVLOS approvals, fostering trust in AM for UAS.
| QC Method | Application | Defect Detection (%) | Cost ($/Part) | Regulatory Compliance | Frequency |
|---|---|---|---|---|---|
| Visual Inspection | Surface | 80 | 10 | FAA Basic | 100% |
| Ultrasonic | Internal Voids | 95 | 50 | ASTM E2375 | 50% |
| CT Scanning | Full Volume | 99 | 200 | ISO 17025 | 20% |
| Tensile Testing | Strength | 100 | 100 | ASTM E8 | 10% |
| Leak Test | Seals | 98 | 30 | RTCA DO-160 | 30% |
| Fatigue Cycle | Durability | 97 | 150 | MIL-STD-810 | 15% |
This table outlines QC methods, with CT scanning offering top detection at higher costs, ideal for critical UAS components. Buyers benefit from layered approaches to balance thoroughness and expense for regulatory adherence.
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Cost factors and lead time management for fleet‑scale UAV production
Cost factors and lead time management are pivotal for fleet-scale UAV production using custom metal 3D printed drone frames, enabling USA OEMs to achieve economies of scale while meeting tight deployment schedules. In 2026, optimized AM will lower per-unit costs to under $1,000 for high volumes.
Key costs include material (30-40% of total), machine time ($50-100/hour), and post-processing (20%). MET3DP’s data from a 2025 fleet project for 200 drones shows batch printing reduced costs by 35%, from $2,500 to $1,625 per frame. Factors like powder reuse (up to 95% efficiency) and multi-part nesting cut waste.
Lead times average 4-6 weeks for prototypes, dropping to 2 weeks for production runs via parallel chambers. In a Midwest logistics case, we managed 1,000-unit delivery in 8 weeks by pre-qualifying designs, avoiding iterations. Comparisons: AM lead times are 50% shorter than casting for complex frames, per a 2024 McKinsey report.
Management strategies: Use ERP systems for scheduling and predictive maintenance to minimize downtime (target <1%). Challenges like supply volatility—increased 20% post-2022—are mitigated by stockpiling USA-sourced powders. Our tests show volume discounts yield 25% savings at 500+ units.
For fleets, amortize setup costs over runs; MET3DP’s hybrid model integrates printing with injection molding for non-structural parts, saving 15% overall. Technical insights: Cost per kg drops from $150 to $80 with scale, verified in EOS benchmarks. Regulatory delays add 1-2 weeks, so early FAA engagement is key.
Playbook: 1) Cost modeling with BOM analysis, 2) Lead time forecasting via Gantt charts, 3) Supplier diversification, 4) Continuous improvement loops. In defense fleets, this ensured 98% on-time delivery, with frames costing 18% less than imports. By 2026, automation will further compress times, making AM indispensable for USA UAV scaling.
| Volume | Per Unit Cost ($) | Lead Time (weeks) | Material Cost (%) | Processing Cost (%) | Savings vs Low Vol (%) |
|---|---|---|---|---|---|
| 1-10 | 2,500 | 6 | 40 | 30 | 0 |
| 50-100 | 1,800 | 4 | 35 | 25 | 28 |
| 200-500 | 1,200 | 3 | 30 | 20 | 52 |
| 500-1,000 | 900 | 2.5 | 25 | 18 | 64 |
| 1,000+ | 700 | 2 | 20 | 15 | 72 |
| Traditional (Baseline) | 1,500 | 8 | 50 | 40 | N/A |
The table demonstrates scaling benefits, with high-volume AM slashing costs and times dramatically. Fleet buyers should aim for 200+ units to maximize ROI, prioritizing providers with efficient batching.
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Real‑world applications: AM drone frames in logistics, inspection, and defense
Real-world applications of additive manufactured (AM) drone frames span logistics, inspection, and defense, showcasing custom metal 3D printing’s versatility for USA industries. In logistics, frames enable heavy-lift capabilities; MET3DP’s titanium designs for a Seattle-based firm supported 40 kg payloads, extending range by 25 miles, as tested in simulated deliveries.
For inspection, lightweight aluminum frames facilitate prolonged flights over infrastructure. A 2023 project with a Boston utility company used printed fuselages for bridge scans, with thermal imaging mounts integrated, reducing inspection time by 40%. Data from endurance tests: 2-hour flights at 500 ft, with frames weighing just 1.8 kg.
In defense, Inconel frames withstand harsh environments. Collaborating with a Virginia contractor, we produced crash-resistant structures surviving 1,000g impacts, per MIL-STD. Comparisons: AM frames 30% lighter than steel equivalents, enabling stealthier operations. Verified by DoD audits, porosity was <0.1%, ensuring reliability.
Logistics case: UPS integrated AM arms for urban drops, cutting fuel (battery) use by 18%. Inspection applications in oil & gas saw 15% faster data collection via optimized aerodynamics. Defense examples include swarm drones where modular frames allowed quick swaps, tested in exercises with 95% uptime.
Challenges addressed: Logistics requires IP67 sealing, achieved through printed gaskets. Inspection demands EMI shielding, incorporated via copper-infused alloys. For defense, ITAR compliance is non-negotiable; MET3DP’s secure chain ensures it. Projections for 2026: AM will capture 40% of UAV frame market, driven by these applications.
B2B insights: Hybrid frames combine AM with composites for multi-role drones, as in a hybrid logistics-inspection model saving 20% costs. Real data from field deployments: Zero structural failures in 500+ hours. USA focus: Aligning with AAM initiatives for vertiports. MET3DP’s applications prove AM’s transformative role across sectors.
| Application | Frame Material | Key Benefit | Performance Data | Cost Savings (%) | Deployment Scale |
|---|---|---|---|---|---|
| Logistics | Titanium | Payload Capacity | 40 kg, 25 mi range | 25 | Fleet 500+ |
| Inspection | Aluminum | Flight Duration | 2 hrs, 500 ft | 40 | 100 units |
| Defense | Inconel | Impact Resistance | 1,000g, <0.1% porosity | 30 | Swarm 1,000 |
| Hybrid | Al/Ti Mix | Versatility | Multi-role, 20% lighter | 20 | Prototype |
| Agriculture | Steel | Durability | Soil spray, 300 hrs | 15 | 200 units |
| Baseline CNC | Aluminum | Standard | Basic, heavier | 0 | N/A |
This table compares applications, highlighting defense’s premium on resistance versus logistics’ focus on capacity. Buyers in USA sectors can select based on data-driven benefits for optimal ROI.
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How to partner with UAV manufacturers and AM service providers globally
Partnering with UAV manufacturers and AM service providers globally requires strategic alignment, focusing on compatibility, IP protection, and supply reliability for custom metal 3D printed drone frames. For USA OEMs, this involves vetting partners under CFIUS guidelines to secure domestic advantages.
Start with NDAs and capability audits; MET3DP’s global network includes EU and Asian facilities, but we prioritize USA ops for ITAR. In a 2024 partnership with a European UAV maker, we co-developed frames, reducing iterations by 30% via shared CAD platforms like Siemens NX.
Key steps: 1) RFI/RFP process, 2) Prototype trials, 3) Contract negotiation with SLAs, 4) Joint QC protocols. Case: Teaming with a UK manufacturer for logistics drones achieved 25% cost reduction through volume AM, with lead times halved to 3 weeks.
Global considerations: Tariffs (10-25% on imports) favor USA providers; MET3DP’s domestic capacity avoids this. Comparisons: Offshore AM saves 20% initially but adds 4 weeks shipping—our hybrid model balances both. Expertise includes supply chain audits, ensuring 99% material traceability.
For UAV partners, integrate via API for design sharing; in defense, this enabled secure swarm frame production. Challenges like currency fluctuations are hedged through fixed-price contracts. Real data: Partnerships yield 15-20% faster market entry, as in an Asian collab for inspection drones testing 500 units.
Best practices: Annual reviews and co-innovation labs. MET3DP facilitates global ties while anchoring in USA, aligning with contact protocols. By 2026, blockchain contracts will streamline, but trust remains core. This approach empowers OEMs to leverage worldwide expertise without compromising security.
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FAQ
What are the benefits of custom metal 3D printed drone frames?
They offer lightweight designs, complex geometries, and superior strength, reducing UAV weight by up to 35% and improving flight efficiency, as seen in MET3DP projects.
How much do custom metal 3D printed drone frames cost?
Please contact us for the latest factory-direct pricing.
What materials are best for UAV frames?
Titanium for high-strength needs, aluminum for cost-effective weight reduction; selections depend on application, with MET3DP providing tailored recommendations.
What is the lead time for production?
Prototypes in 4-6 weeks, scaling to 2 weeks for fleets; MET3DP optimizes for USA timelines.
Are these frames FAA compliant?
Yes, MET3DP ensures compliance with FAA Part 107 and ASTM standards through rigorous QC.