Windracers is one such partner, a UK-based company revolutionising air cargo using its dual-use heavy-lift drone, Windracers ULTRA. Designed for long-range, heavy-lift missions, Windracers ULTRA serves critical applications such as defence, humanitarian aid, environmental monitoring and civil air cargo – often in locations too dangerous or remote for traditional crewed aircraft.
When Windracers needed a manufacturing partner capable of delivering lightweight, highly engineered and production-ready components, they turned to Prototal. Our deep expertise in industrial 3D printing, combined with a proven track record in aerospace and mobility production for over 25 years, made us a natural choice for a mission where precision, repeatability and regulatory compliance were essential.
This case study explores how we supported Windracers optimising the performance of ULTRA – from design to serial production – all while meeting the demands of a mission-critical customer requirements.
In developing ULTRA as a heavy-lift cargo drone, Windracers faced a significant engineering challenge: reducing overall weight and production costs while maintaining the strength, durability and performance needed for mission-critical operations of their engine cowlings. Originally, many of ULTRA’s structural and internal components were manufactured from metal leading to higher tooling costs, extended lead times and unnecessary weight. The success of the engine cowlings quickly built trust between the engineering teams, leading to further opportunities for collaboration.
These are protective covers that enclose an aircraft’s engines, helping to streamline airflow, reduce drag, and protect internal components from environmental exposure. Produced in lightweight polymer, cowlings contribute to overall aerodynamic efficiency without adding unnecessary mass.
In order for ULTRA to carry loads of up to 150 kg of supplies, travel up to 1,000 km and remain airborne for up to 10 hours, weight is a crucial factor. Every gram saved translated to longer endurance, increased range and improved fuel efficiency – essential for delivering cargo into regions where traditional supply chains are compromised or where it is too dangerous to send crewed aircraft.
As Windracers saw the advantages of additive manufacturing in both lead time and design flexibility, two additional components were introduced into the production workflow:
Windracers partnered with Prototal to explore advanced polymer solutions. By switching from metal to Nylon 12 – produced via industrial 3D printing – Prototal helped Windracers to significantly reduce weight, eliminate the need for costly tooling and decrease lead times.
“By removing the need for tooling meant that design improvements could be developed without financial constraint; unlimited iterations and improvements not just to design but also important for improving production” Meirion Rees, Production & Maintenance Lead.
“The transition to lightweight polymer components has not only reduced costs but also improved aircraft performance. The ULTRA now delivers reliable, long-range capability in high-risk environments, making it a valuable asset for humanitarian missions and national defence” Stephen Krajewski, Marketing Director
