Meet Boresight: Pioneering Drone Innovation for the Modern Battlefield
Boresight is a leading Australian innovator in aerial target systems and unmanned aerial vehicles (UAVs), delivering world-class solutions for defense training and tactical simulation. Their core mission is to provide reliable, high-performance drones capable of replicating real-world combat conditions, enabling military forces to train smarter, safer, and more effectively.
With decades of field experience, Boresight’s drones are not just training tools—they are engineering achievements that push the boundaries of what’s possible in aerial defense technology. The company has built a reputation for rapid design iteration, durable construction, and unmatched operational precision, all while staying responsive to the evolving needs of defense clients.
To further improve performance and production agility, Boresight has integrated advanced Selective Laser Sintering SLS 3D Printing into its workflow. This shift allows for greater design freedom, increased material efficiency, and the ability to rapidly prototype and deploy new parts—all critical in high-demand defense environments.
Working in close partnership with Thinglab, Boresight has adopted the Formlabs Fuse Series SLS printers to unlock a new level of in-house manufacturing capability. This collaboration not only enhances their production speed and scalability but also positions Boresight as a technological leader in Australia’s growing drone and aerospace sector.
A New Era in Aerospace: How Boresight is Transforming Drone Manufacturing in Australia with SLS 3D Printing
The rapid evolution of military and industrial drone technology demands innovative manufacturing solutions. Boresight, an Australian drone manufacturer, has embraced SLS 3D printing to develop high-performance, mission-ready UAVs. By leveraging the Formlabs Fuse Series and partnering with Thinglab, Boresight has been able to streamline production, reduce costs, and enhance drone capabilities for military applications.
Why SLS 3D Printing is a Game-Changer for Aerospace and Defense
Breaking Free from Traditional Limitations Traditional drone manufacturing relies on CNC machining, injection molding, and FDM 3D printing, all of which have limitations in terms of cost, scalability, and material performance. SLS (Selective Laser Sintering) 3D printing overcomes these challenges by enabling complex geometries without the need for support structures.
High Performance, Low Waste This technology simplifies the design process and creates stronger, more durable parts. With high packing density, SLS reduces material waste while speeding up both prototyping and production.
Engineering-Grade Materials for Mission-Ready Drones
Strength in Every Layer For Boresight’s military-grade drones, durability and weight are critical. The Formlabs Fuse 1+ 30W supports advanced nylon powders ideal for aerospace applications:
- Nylon 12 Powder: Impact-resistant and perfect for UAV structures.
- Nylon 11 Powder: Flexible and tough, ideal for parts requiring flexibility.
- Glass-Filled Nylon 12G: Reinforced for high-stress components like chassis and mounts.
From Target Drones to Tactical UAVs: Boresight’s SLS Journey
Upgrading from FDM to SLS Originally, Boresight relied on FDM to produce expendable drones for training. But as demand shifted toward real-world mission drones, they needed more robust, consistent solutions.
Enter the Formlabs Fuse 1+ 30W SLS 3D Printing allowed them to manufacture lightweight, high-strength parts with faster turnaround times. The result? Better durability, streamlined production, and cost efficiency—all without sacrificing quality.
Lean, Agile, and Efficient: The Power of Smart Manufacturing
Efficient Use of Space and Material With SLS, Boresight packs components tightly—drone arms, battery compartments, camera mounts—maximizing build efficiency and minimizing cost.
Built for Scalability These efficiencies let them produce structurally sound parts at a fraction of the traditional manufacturing cost.
The Formlabs Fuse Series: Industrial-Grade Power, Desktop Footprint
Why Fuse is the Ideal In-House SLS Solution Compact and powerful, the Formlabs Fuse 1+ 30W is perfect for small-to-medium-sized manufacturers. Features include:
- 30W laser for faster print times
- Closed-loop powder handling
- Broad compatibility with advanced materials
Fuse Blast for Seamless Post-Processing The Fuse Blast system automates media blasting, reducing manual labor by 80% while delivering a clean, injection-molded look to printed parts.
Future-Proofing Drone Production with Design Flexibility
Rapid Iteration for Real-Time Innovation Need to adjust a drone design overnight? No problem. SLS enables on-demand manufacturing, which is essential for adapting to changing mission specs, payloads, or supply conditions.
No More Tooling Bottlenecks Say goodbye to $100,000+ molds and long tooling lead times. SLS makes low-volume, high-precision manufacturing affordable.
Smarter, Greener Manufacturing
Sustainability Through Powder Recycling Unused powder can be recycled for future prints, making SLS more environmentally friendly and reducing overall material waste.
Why Australian Businesses are Turning to Formlabs & Thinglab for manufacturing and help with SLS 3D Printing.
Accessible, Scalable, and Supported Australian manufacturers are embracing the Formlabs Fuse Series for its cost-efficiency and reliability. With expert guidance from Thinglab, companies like Boresight are adopting SLS 3D printing with confidence.
More Than a Supplier: Thinglab’s End-to-End Support From training and setup to ongoing consultation, Thinglab ensures that Australian manufacturers can fully leverage the benefits of industrial-grade 3D printing. The result? Innovation, efficiency, and industry leadership in drone technology.
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