When a UAV platform weighs less, it carries more. When a structural housing is engineered as a single monolithic component—integrating electronics, batteries, and communication boards—it inherently reduces failure modes.
These are not theoretical advantages. They are the tangible outcomes of additive manufacturing with High-Performance Composites—the core expertise of CRP USA—setting new standards for reliability and integration across modern aerospace and defense programs.
Leveraging advanced Windform® carbon- and glass-fiber reinforced composites for Selective Laser Sintering (SLS), CRP USA delivers proven high-strength, lightweight structures engineered for rapid deployment in extreme environments.
Structural Consolidation: The Case Against Multi-Part Assemblies
Conventional defense hardware accumulates risk with every additional fastener and bonded joint. CRP USA centers on structural consolidation—integrating discrete components into a single engineered unit enabling complex internal geometries - such as integrated cable routing and sensor housings - that are impossible or cost prohibitive using conventional manufacturing.
Measured outcomes include:
- Up to 60% weight reduction versus multi-part assemblies.
- Reduced assembly time and simplified integration.
- Optimized payload and enhanced mission endurance.
- Compressed production cycles for rapid deployment.
Modernization and Retrofit: Accelerated HMSD Integration
Integrating advanced Helmet-Mounted Sight and Display (HMSD) systems into legacy platforms introduces structural and electromagnetic constraints. These architectures demand mounting solutions that ensure both mechanical precision and electrical integrity.
Windform® materials (LX3.0, FR2, and GT) provide a distinct advantage through superior dielectric performance and structural reliability.
Key technical enablers:
- High dielectric strength: Allows safe embedding of electronics, minimizing interference.
- Seamless electro-mechanical integration: Circuits and sensors coexist within load-bearing geometries.
- Signal integrity: Mitigates parasitic electromagnetic effects in high-density architectures.
- Geometric precision: Supports complex retrofits without compromising legacy platform constraints.
Windform® Performance in Operational Conditions
Windform® composites are purpose-engineered for operational extremes, with proven validation across global programs:
- Environmental Resilience: Qualified through shock, vibration, and thermal cycling from -20°C to +49°C.
- Integrated Electronics: Glass-fiber options offer high dielectric performance for radomes and RF-transparent enclosures. Alternatively, carbon-fiber variants provide controlled EMI shielding for active electronics.
- Space Flight Heritage: Validated across multiple launcher missions and 57pocket Qube deployments. Low outgassing and reliability under vacuum and radiation make it ideal for LEO applications.
The combination of ultra-low density and durability makes Windform® essential for SWaP-C constrained platforms. Our ITAR-registered supply chain ensures immediate access for US defense programs without compliance friction.
Expert Consultation for Additive Manufacturing
CRP Group capabilities in Design for Additive Manufacturing (DFAM) have been honed through years of cooperation with leading motorsport defense and avionics experts. This experience has given the CRP Group team a deep understanding of the specific requirements of aerospace applications.
This approach significantly reduces the time between the conceptual validation of an idea and its evolution into a functional prototype facilitating iterative refinement of the project.
Meet CRP Group in 2026
Connect with our engineering team at these upcoming events:
- XPONENTIAL Europe — Düsseldorf, Germany | March 24–26 |Booth E71, Hall 01
- RAPID + TCT — Boston, US | April 14–16 | Booth 2443
- Free Expo Pass: Promo code 14068086 | 20% off conference registration
- AUVSI XPONENTIAL — Detroit, US | May 12–14 | Booth 16031
