Northwest UAV (NWUAV) was founded in 2005 by Chris Harris to produce highly efficient engine systems for the growing Unmanned Aerial Vehicle (UAV) industry.

Today, NWUAV employs over 80 people at its headquarters in McMinnville, Oregon, and generates over $20 million in annual revenue.

The Problem

A Better Way to Assemble, A Better Way to Test

NWUAV builds engines for numerous models of Unmanned Aerial Vehicles (UAVs), which have several universal components. NWUAV engineers developed a component known as a “puck” that would hold the standard engine parts and easily slide into the engine compartments of several models. This innovation dramatically reduced assembly time on the engines.

NWUAV was working within a short timeline to produce complete engine assemblies. To meet the demand, the engineering department required a rapidly produced prototype to physically check the fit and function of the puck, which has a complex geometry. The engineers chose Selective Laser Sintering (SLS) additive manufacturing to create the prototype, utilizing two 3D printing bureaus: NW Rapid Manufacturing and a large service bureau located out of state.

The large bureau produced a puck that came in on the high side of NWUAV’s tolerances. The large bureau version puck had “orange peel” surface defects, which indicates a low-quality powder, and the part appeared to have been hand-sanded to improve the finish. The engineering team also noted the part was stiff, the features had poor resolution, and, most importantly, it weighed 159 grams.

The Solution

A Better Puck

NW Rapid Manufacturing printed the component puck on an EOS P7-series machine using EOS PA2201. With no change to the 3D file, NW Rapid produced an accurately dimensioned puck with a high-quality, smooth finish, good flexibility, and a “crisp” appearance. Most importantly, the puck weighed in at only 148 grams.

For more information, please don't hesitate to contact us at or request a quote and upload your file today!