# Building Drones at Scale: SLS Production from Low-Volume to High-Rate Manufacturing

- Show: [Additive Snack](https://hardwarepodcasts.com/podcast/additive-snack)
- Published: 2026-09-29
- Length: 44m
- Episode: 42
- Page: https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi
- Listen: https://share.transistor.fm/s/7825cdf1

## Summary

Nick Classen, General Manager of Northwest Rapid Manufacturing, explains how the company evolved from supporting Northwest UAV into a high-rate production provider for UAVs using EOS SLS technology. He details the shift from prototyping to end-use parts, highlighting specific applications like conformal fuel tanks, EMI-shielded housings, and structural brackets made from Nylon 12, Alumide, and glass-filled polymers. Classen discusses the operational challenges of scaling production, the critical role of post-processing, and the company's strategic expansion into metal AM (DMLS) to meet growing defense and aerospace demand.

## Chapters

- [0:06](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=6) Introduction and Company Origins
- [3:58](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=238) Strategic Value of AM for UAVs
- [6:40](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=400) Early Design Engagement and DFAM
- [10:27](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=627) Low-Rate vs. High-Rate Production Volumes
- [12:29](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=749) Scaling for Market Growth and Consolidation
- [14:49](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=889) Key UAV Applications: Fuel Tanks and Structures
- [20:04](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=1204) Advanced Materials: Alumide and Glass-Filled Polymers
- [22:21](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=1341) Post-Processing, Coating, and EMI Shielding
- [28:38](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=1718) Expansion into Metal AM and Other Industries
- [36:09](https://hardwarepodcasts.com/podcast/additive-snack/2026-09-29-building-drones-at-scale-sls-production-from-low-volume-to-high-rate-manufacturi#t=2169) Scaling Operations and Workforce Challenges

## Topics

- [Scaling production](https://hardwarepodcasts.com/topic/scaling-production)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)
- [Hiring & workforce](https://hardwarepodcasts.com/topic/hiring-and-workforce)
- [Industrial & consumer product design](https://hardwarepodcasts.com/topic/industrial-design)

## Most relevant to

companies scaling up

## Mentioned

- Northwest Rapid Manufacturing (company)
- Northwest UAV (company)
- EOS (company)
- Situ (company)
- Archer (company)
- Nylon 12 (material)
- Alumide (material)
- DMLS (tool)
- EMI shielding (other)

## Related episodes from other shows

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- [S2 E5: Rapid Prototyping Deep Dive with Greg Paulsen](https://hardwarepodcasts.com/podcast/the-builder-circle/2024-01-23-s2-e5-rapid-prototyping-deep-dive-with-greg-paulsen) (The Builder Circle)
- [Dylan Lundberg | Protolabs](https://hardwarepodcasts.com/podcast/being-an-engineer/2022-08-05-dylan-lundberg-protolabs) (Being an Engineer)
- [HIBT Lab! Ursa Major: Joe Laurienti](https://hardwarepodcasts.com/podcast/how-i-built-this/2023-04-20-hibt-lab-ursa-major-joe-laurienti) (How I Built This)
- [Daniel Lazier | How to Make Super Strong Parts Fast & Inexpensively - Markforged](https://hardwarepodcasts.com/podcast/being-an-engineer/2022-07-29-daniel-lazier-how-to-make-super-strong-parts-fast-inexpensively-markforged) (Being an Engineer)

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