At Graphite Additive Manufacturing, we’re passionate about enabling innovation through advanced 3D printing technologies. We are proud to announce our partnership with Cranfield University’s Unmanned & Intelligent Aerial Systems (UIAS) Society in IMechE UAS Challenge 2025.
This collaboration highlights our commitment to advancing emerging UAS technologies, supporting STEM outreach, and nurturing the next generation of engineering talent.
About the IMechE UAS Challenge
Now in its 11th year, the IMechE UAS Challenge – the globally recognised competition, organised by the Institution of Mechanical Engineers (IMechE), brings together university teams worldwide to design, build, and fly unmanned aircraft for real-world humanitarian missions. The 2025 challenge focused on medical aid delivery for search and rescue in disaster-stricken regions, testing teams on innovation, technical execution, and teamwork.
Cranfield University’s UIAS Society
Founded in 2018 under the Cranfield Students Association, the UIAS Society is a student-led group dedicated to advancing drone technology. It provides a platform for students to engage in hands-on UAS projects and compete in prestigious global challenges.
The 2025 team, combined from MSc students from Aerospace, Autonomous Vehicle Dynamics and Control, Air Transport Management, Data Science and AI for Sustainability, Strategic Marketing, and Global Product Development, brought together a wealth of expertise, hands-on drone operation experience and prior UAS Challenge involvement.
Competition Highlights
The competition involved multiple phases, including documentation (Concept Paper, PDR, CDR, DDR, and X-Plane simulations) and an in-person event at BMFA Buckminster. The team assembled their 10kg VTOL drone, successfully presented to judges, passed scrutineering, and completed the unboxing challenge.
While a late wiring issue prevented live flying during the event, subsequent modifications by the team led to a flawless flight demonstration shortly afterwards.
How Graphite AM Added Value
Graphite Additive Manufacturing supported the team by 3D printing critical components for the aircraft using Multi Jet Fusion (MJF) PA12 technology.
This brought three key advantages to the teams project:
- Freedom of Design – enabled a complex, aerodynamically optimised fuselage not possible with traditional wooden or foam builds.
- Weight Savings – produced a lightweight yet durable structure, improving efficiency and performance.
- Speed & Time – allowed rapid prototyping and faster turnaround, keeping the project on schedule.
The result was a professional-grade fuselage that significantly enhanced the aircraft’s durability, performance, giving Cranfield team a competitive edge.
Recognition on the Global Stage
Judges and industry representatives praised the Cranfield drone’s refined engineering, durable fuselage, and polished presentation, setting it apart from other entries.
The collaboration not only boosted the team’s performance but also demonstrated the potential of additive manufacturing in advancing UAS technology.
A Word from the Cranfield UIAS Team
“We are immensely grateful for Graphite Additive Manufacturing’s expertise and support in 3D printing our aircraft components. Their contributions elevated our drone’s design to new heights, making it one of the most distinctive and innovative entries in the competition. We received numerous compliments from judges, potential sponsors and industry leaders like Leonardo, Callen-Lenz, BAE Systems, highlighting the fuselage’s professional quality and advanced materials.
This partnership has been instrumental in helping us achieve our goals, and we look forward to deepening our collaboration on future projects to continue pushing the boundaries of UAS technology.”
Statement from the Managing Director at Graphite Additive Manufacturing, Kevin Lambourne
“We are thrilled to partner with Cranfield University’s UIAS Society for the 2025 IMechE UAS Challenge. Supporting the team’s innovative vision with our advanced 3D printing capabilities was a privilege, and seeing their VTOL drone stand out for its unique design and professional quality was incredibly rewarding.”
Looking Ahead
This achievement marks the beginning of a long-term partnership between Graphite AM and Cranfield University. We remain committed to supporting STEM outreach, student-led innovation, and the next generation of engineers, while showcasing the potential of additive manufacturing in UAS and beyond.
Stay tuned for updates on our projects and partnerships. To explore how Graphite can support your additive manufacturing needs, get in touch today.
