this post was submitted on 27 Aug 2025
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3D printing can be cost effective for small production runs too. There are large format printers both FDM and SLA with print quality, large bed size and speed more than sufficient.
Injection molding is only cheap when print runs are huge. In a rapidly developing space like drone warfare, a lot of plastic parts get changed frequently enough that injection molding becomes cost prohibitive, due to small production runs between design changes.
Take the example of a propeller vs a custom bracket to hold a new type of clip for ammo.
Propellers can be standardized according to motor, frame geometry, and power source parameters, so they can be mass produced with injection molding by the ton.
A bracket needed to test out a new configuration may only be made in runs of a few hundred before some other update changes things again.
All this is to say that drone warfare is logistically an insanely complex supply chain to manage.
3D printing will have a role in drones that see combat until the day the designs are completely perfect and never need to be changed again. Then the economy of scales can overcome the high setup costs of building an injection mold.
And the Pentagon will stockpile them by the billions to give SkyNet something to work with later. yay.