Lightweight Aerospace Bracket
Challenge
An aerospace client needed a lightweight, high-strength bracket for a UAV airframe.
The component required tight tolerances, temperature stability, and resistance to vibration—all while reducing overall weight to improve flight efficiency.
Traditional CNC machining was too slow, too costly, and required multiple design revisions.
Solution
ProtoAero’s engineering team partnered with the client to optimize the design for additive manufacturing using topology optimization and material analysis.
We selected carbon fiber–reinforced nylon (PA12-CF) for its strength-to-weight ratio and thermal performance.
The project followed our end-to-end workflow:
Design optimization for additive (DfAM)
3D printing on HP Jet Fusion 5200 system
Post-processing and surface finishing for dimensional accuracy
Load testing and validation to confirm flight-readiness
Client Feedback
“ProtoAero’s team turned what was a manufacturing bottleneck into a performance advantage. Their engineering support and turnaround speed were unmatched.”
— Lead Aerospace Engineer, Toronto-based UAV Company
