In-House Drone Production: Over 80% SLS Parts at ION Mobility

Posted by FIT THAI on January 20, 2026

ION Mobility is a drone manufacturer from South Korea that designs and builds advanced UAV systems specifically for public safety, defense, logistics, and industrial applications. Their drones are actively used in field missions, ranging from surveillance to emergency response, equipped with high-resolution cameras, thermal imaging systems, and secure communication systems. With the growth of the Urban Air Mobility (UAM) concept, ION Mobility has also developed an AI-driven autonomous flight system to ensure that drones can operate efficiently, reliably, and safely in complex environments.

However, bringing these innovations to life requires a manufacturing process that is as fast and flexible as the technology they develop. The ability to rapidly iterate designs, produce high-performance parts, and tackle new design challenges is crucial in this highly competitive industry.

Limitations of Traditional Manufacturing Processes

Before adopting 3D printing technology, ION Mobility relied on outsourcing to manufacturers to produce drone parts using traditional machining processes. This method of production involves subtractive manufacturing, where parts are milled from blocks of plastic, leading to several limitations. The production lead time is relatively long, especially when modifications are made, and the costs associated with design changes increase rapidly. Traditional manufacturing techniques may be suitable for mass production but fall short when it comes to low-volume, highly complex tasks, which are characteristic of lightweight UAV parts ready for real-world use. Thus, ION Mobility sought a new solution, one that could reduce both production time and costs while maintaining the highest performance of the parts.

From Limitations to Transformation with Fuse 1+ 30W

ION Mobility's drones can carry significant payloads, and the main body structure is strong, durable, and lightweight, all thanks to the use of SLS 3D printing technology and advanced SLS material powders from Formlabs, such as Nylon 12 GF Powder.

To address manufacturing challenges, ION Mobility implemented SLS printing technology in-house, opting for the Formlabs Fuse 1+ 30W. The team needed a system that could quickly produce functional parts, accommodate complex shapes, and allow for design iterations as needed. Fuse 1+ 30W met these requirements effectively. The printer enables ION's engineers to print general parts in just about 7 hours, and even high-density jobs can be completed overnight, in approximately 14 hours. With Selective Laser Sintering (SLS) technology, there is no need for support structures, allowing for the easy printing of complex shapes without compromising strength or accuracy. Additionally, Formlabs' patented Surface Armor technology ensures that printed parts have a consistent, professional surface, ready for testing or immediate installation on drones.

“With Fuse 1+ 30W, we can complete prints in half a day, even for complex designs. What used to take a long time and be costly has become a much faster and more cost-effective process.”

Sukchun Son, Senior Manager, ION Mobility

Enhancing Performance with Nylon 12 GF Powder

Designing a drone is only half the equation. Material selection plays an equally important role in producing reliable drone parts. For ION Mobility, Formlabs' Nylon 12 GF Powder provides the performance they need. This glass-filled nylon is strong and highly heat-resistant, making it ideal for UAV parts that face high temperatures and structural stresses. ION's engineers can create a lightweight yet strong drone frame, produce improved heat-resistant motor mounts, and design highly precise mission equipment housings for various sensor installations. The result is critical flight components that can operate reliably under pressure and in real-world applications.

Tangible Results: Faster Development and Reduced Costs

The Fuse Series SLS ecosystem is an accessible workflow that still provides industrial-level production power, capable of producing high-quality parts without the need for the infrastructure or large footprint of traditional Powder Bed systems.

After implementing the Fuse 1+ 30W in their manufacturing process, ION Mobility was able to reduce development costs by up to 60% and increase operational speed by 70%. Prototypes that once took weeks to produce can now be completed in just a few days, or even a few hours.

Engineers can iterate designs freely without worrying about mold costs, and parts that were previously too complex or expensive to produce can now be printed on demand. The Fuse 1+ 30W has thus become not just a tool but a vital part of the team's innovation strategy. From the development team's perspective, the ability to produce high-performance, specialized parts in-house has significantly enhanced the capabilities of ION Mobility's tactical drones. Where traditional manufacturing was once a limitation, in-house SLS printing has opened new design opportunities and allowed ION to move faster than competitors.

Breaking Through Flight Limitations

ION Mobility's drones are advanced machines, which makes production costs relatively high. However, the Fuse Series has helped reduce R&D costs by 60% and increase development speed by 70%, enabling them to bring products to market faster and maintain a competitive edge.

As the demand for agile, robust, and intelligent drones continues to rise, ION Mobility is poised to step up as a leader. Investing in the Fuse 1+ 30W and Nylon 12 GF Powder has allowed the team to innovate without limits and scale production confidently. From prototyping to actual production, they have taken full control of the entire development process, delivering smarter, safer, and more efficient drone solutions to market faster than ever.

“With traditional manufacturing methods, production times were long, and design changes were costly. But now, even the most complex parts can be printed in half a day and at a lower cost.”

Sukchun Son, Senior Manager, ION Mobility

By integrating cutting-edge hardware, advanced materials, and forward-thinking concepts, ION Mobility is redefining the possibilities of drone development and demonstrating what it means to “build without limits.”