Prototal collaborated with Windracers, a UK-based aerospace company, to support the development and production of lightweight polymer components for Windracers ULTRA, a long-range, heavy-lift cargo drone. By replacing metal parts with industrially 3D printed PA 2200 (Nylon 12), Prototal helped reduce weight, shorten lead times, and enable ongoing design optimization for mission-critical aerospace applications.
Windracers develops autonomous, fixed-wing cargo aircraft designed for long-range operations in environments where traditional crewed aviation is impractical or unsafe. Their aircraft, Windracers ULTRA, is designed to carry payloads of up to 150 kg, fly distances of up to 1,000 km, and remain airborne for up to 10 hours. The platform is used across applications including humanitarian logistics, environmental monitoring, civil air cargo, and defense support — often in remote or high-risk regions.
The Challenge
During the development of ULTRA, Windracers faced the challenge of reducing aircraft weight and production cost without compromising strength, durability, or performance.
Several components were originally manufactured from metal, resulting in:
- Increased weight
- High tooling costs
- Longer lead times
- Reduced flexibility for design iteration
For a long-range, uncrewed aircraft, even small weight reductions directly affect endurance, range, and fuel efficiency, making material and manufacturing choices critical.
Manufacturing Approach
Prototal’s site in the UK collaborated with Windracers to transition selected components from metal to Industrial 3D Printing in polymer.
Technology and Material Selection
- Industrial 3D Printing technology Selective Laser Sintering (SLS)
- PA 2200 (Nylon 12), selected for strength-to-weight ratio, durability, and repeatability
- Tool-free production, enabling rapid iteration and cost control
This approach eliminated the need for tooling while supporting production-ready part quality with short lead times.
Produced Components
Following the successful development of the initial components, the collaboration expanded to include multiple aircraft parts:
Engine Cowlings
Lightweight polymer cowlings were produced to protect the engines, improve aerodynamic efficiency, and reduce overall aircraft mass. The reduced weight contributed directly to improved range and endurance.
Lower Strut Fairings (Starboard Side)
Snap-fit fairings designed to attach around the landing struts, improving airflow while simplifying assembly and maintenance. The printed polymer design combined durability with minimal weight.
Antenna Holder
A precision-engineered bracket designed to secure the aircraft’s antenna during long-range flight. The component was produced to withstand vibration and environmental exposure, supporting reliable communication and navigation.
Collaboration and Iteration
By removing tooling constraints, Prototal enabled Windracers to:
- Iterate designs without additional upfront investment
- Introduce continuous improvements to both part geometry and production efficiency
- Reduce lead times for updated components
“Removing the need for tooling meant that design improvements could be developed without financial constraint. We got access to unlimited iterations and improvements not just to design better but also for improving production.”
— Meirion Rees, Production & Maintenance Lead, Windracers
Results
The transition to industrially 3D printed polymer components delivered measurable benefits:
- Reduced component weight and overall aircraft mass
- Lower production costs compared to machined metal parts
- Shorter lead times and faster design iteration
- Improved aircraft performance in long-range and high-risk missions
- A scalable manufacturing approach suitable for serial production
“The transition to lightweight polymer components has not only reduced costs but also improved aircraft performance.”
— Stephen Krajewski, Marketing Director, Windracers
This collaboration demonstrates how Industrial 3D Printing can support aerospace-grade, production-ready components where weight reduction, repeatability, and flexibility are critical. Through the use of SLS PA 2200 (Nylon 12), Prototal supported Windracers in optimizing the ULTRA platform for demanding operational environments, while enabling continuous development without the limitations of traditional tooling.
As a result of our collaboration, Windracers has grown to become an important strategic partner in this sector. It is a testament to the strength of our partnership and the critical role Industrial 3D Printing plays in modern aerospace innovation, we continue to challenge each other to drive innovation.”
– Martin Nottingham, Managing Director at Prototal UK
