Charles R. Goulding and Preeti Sulibhavi explore how General Atomics is revolutionizing aerospace, defense, and energy with groundbreaking 3D printing and advanced composites technologies.
General Atomics is a defense and diversified technologies company founded in 1955 as a division of General Dynamics but has since been purchased privately. It is headquartered in San Diego, California and employs over 12,500 employees as of the end of 2024.
In the ever-evolving landscape of technology and engineering, General Atomics (GA) stands as a beacon of innovation. Renowned for its groundbreaking work in defense, energy, and aerospace, the company has embraced cutting-edge technologies like 3D printing, to push the boundaries of design and performance. Additionally, their expertise in performance composites has enabled the development of lightweight, durable, and high-performance components critical to modern applications. General Atomics integrates 3D printing and performance composites into its operations to push the boundaries of technology and engineering.
3D Printing in Modern Manufacturing
3D printing has transformed manufacturing by enabling rapid prototyping, on-demand production, and intricate designs that are often impossible to achieve with traditional methods. At its core, additive manufacturing involves creating objects layer by layer, offering enhanced precision, material efficiency, and design flexibility. Industries ranging from aerospace to healthcare have adopted this technology, and General Atomics has been at the forefront of its application.
For GA, the adoption of 3D printing is not just about staying ahead in the competitive landscape but also about redefining how advanced systems are developed and maintained. By integrating this technology, GA has reduced production timeframes, optimized costs, and improved the performance of critical systems.

Performance Composites: A Perfect Match
Performance composites—engineered materials made from fibers like carbon or glass embedded in a resin matrix—offer unparalleled strength-to-weight ratios, thermal resistance, and durability. These materials are essential in aerospace and defense, where weight reduction and material reliability can significantly impact operational efficiency. General Atomics has combined the strengths of performance composites with 3D printing to create components that meet the most demanding specifications.
The synergy between these two technologies has led to remarkable innovations, allowing GA to produce highly customized parts for drones, energy systems, and other high-performance platforms. By leveraging these advancements, GA continues to enhance its offerings while addressing challenges like sustainability and cost-effectiveness.
Four Examples of General Atomics Using 3D Printing
1. Prototyping for Predator Drones
General Atomics Aeronautical Systems, Inc. (GA-ASI), a subsidiary of GA, has integrated 3D printing into the development of its Predator series drones. The Predator, one of the most iconic unmanned aerial vehicles (UAVs) in military history, has benefited from 3D printed components in its prototyping phase.
3D printing has allowed GA-ASI engineers to rapidly produce and test aerodynamic parts, enabling quicker design iterations. This capability has been particularly beneficial for optimizing the drone’s payload capacity and flight dynamics. Additionally, GA-ASI’s recent development of an electric launch system for UAVs, as reported by The Aviationist, has further highlighted the role of advanced manufacturing. By using 3D printed components in the design of the launch system, GA-ASI has achieved improved energy efficiency and reduced reliance on traditional launch infrastructure. This innovative approach underscores the adaptability and effectiveness of 3D printing in meeting evolving operational demands.

2. Collaborations with Divergent Technologies
In recent years, GA-ASI has partnered with Divergent Technologies, a company specializing in advanced manufacturing techniques, including 3D printing. This collaboration focuses on creating next-generation components for UAVs and other aerospace platforms. Divergent’s proprietary 3D printing processes have been instrumental in producing lightweight yet robust structures for GA-ASI systems.
For instance, Divergent’s technology was used to manufacture key structural elements of UAV fuselages. These components demonstrated improved strength and durability while significantly reducing overall weight, contributing to enhanced fuel efficiency and longer operational ranges. The partnership exemplifies how additive manufacturing can revolutionize aerospace engineering.
3. Additive Manufacturing in Magnetic Fusion Energy Systems
General Atomics has also applied 3D printing to its work in magnetic fusion energy research. As a leader in fusion energy development, GA has used 3D printing to create intricate components for its advanced Tokamak reactors.
Fusion reactors require highly specialized parts capable of withstanding extreme temperatures and pressures. 3D printing has enabled the production of such components with unparalleled precision. For example, GA has used 3D printing to fabricate plasma-facing materials and other critical elements, enhancing the performance and reliability of their experimental reactors. These advancements have brought GA closer to achieving practical and sustainable fusion energy.
4. Custom Tooling and Maintenance Solutions
In addition to manufacturing new components, General Atomics has utilized 3D printing to streamline tooling and maintenance processes. Traditional manufacturing methods for specialized tools often involve long lead times and high costs. By employing additive manufacturing, GA has created custom tools and fixtures tailored to specific applications.
One notable example involves maintenance for GA’s UAVs and energy systems. Additive manufacturing has allowed the company to produce on-demand replacement parts, minimizing downtime and reducing inventory costs. This approach not only enhances operational efficiency but also aligns with sustainability goals by reducing material waste.

Advancing the Role of Performance Composites
Beyond 3D printing, GA has leveraged performance composites to further its technological capabilities. In drone manufacturing, for instance, carbon fiber composites have been used extensively to reduce weight while maintaining structural integrity. These materials have enabled UAVs to achieve longer flight times and carry heavier payloads without compromising performance.
Moreover, performance composites have been critical in the development of GA’s energy systems. The combination of composite materials and 3D printing has allowed for the creation of complex geometries that maximize efficiency and durability. This integration is particularly evident in components for fusion reactors, where the materials’ thermal and mechanical properties are paramount.
The Future of Additive Manufacturing at General Atomics
As General Atomics continues to push the boundaries of innovation, additive manufacturing and performance composites are expected to play an even more prominent role. The company’s investment in these technologies demonstrates its commitment to advancing engineering solutions across defense, aerospace, and energy sectors.
Emerging trends such as multi-material 3D printing and advanced composite formulations hold immense potential for GA’s future projects. By staying at the forefront of these developments, General Atomics is well-positioned to address the complex challenges of the modern world while maintaining its status as an industry leader.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
General Atomics’ integration of 3D printing and performance composites exemplifies the transformative power of advanced manufacturing technologies. From improving drone designs to enhancing fusion energy systems, these innovations have allowed GA to achieve remarkable feats in engineering and technology. As the company continues to explore new frontiers, its commitment to leveraging cutting-edge methods ensures a future of groundbreaking achievements and profound impact.