The collaboration between Divergent Technologies and Saab has resulted in a 4.5-meter fuselage composed of just 26 printed metal parts, assembled using an automated robotic automated robotic system. This approach eliminates molds and jigs, relying on the DAPS adaptive production system, which integrates digital design, AI optimization and automated assembly.
The DAPS (Divergent Adaptive Production System) uses laser powder bed fusion technology and generative design algorithms to distribute material efficiently, resulting in lightweight and strong structures.
Defense and aviation 3D airframe applications
This airframe is intended for a prototype unmanned aircraft unmanned aircraft that Saab plans to test-fly in 2026. test flight in 2026.. The modular design allows for quick adjustments through modifications to the digital file, which significantly reduces development times.
According to Axel Bååthe, head of Saab’s The Rainforest innovation lab, this flexibility represents a paradigm shift: “We want manufacturing to be as flexible as software.”
Scalability and structural performance
The developed airframe demonstrates that it is possible to scale additive manufacturing additive manufacturing to levels relevant to defense and aviation and aviation systems. By removing the need for specific tooling, the process becomes more cost-effective and adaptable to real-time design changes.
Lukas Czinger, CEO of Divergent, pointed out that the Divergent DAPS system enables complex structures to be manufactured with a speed and efficiency that conventional methods cannot match. This technology is also being applied in sectors such as automotive and aerospace.
The project marks a breakthrough in the integration of artificial intelligenceadditive manufacturing and robotic assembly in the aeronautics industry. If the flight tests are successful, Saab plans to extend this methodology to more complex platforms within its air defense systems.
Source and photo: Divergent