CRP USA, a leading 3D printing service bureau, will be exhibiting at Xponential AUVSI 2025, taking place from May 19-22, 2025 in Houston at the George R. Brown Convention Center, booth 2038. The company will be showcasing its innovative use of Selective Laser Sintering (SLS) 3D printing in combination with Windform composites to create high-performance components for the autonomy, aerospace, and Unmanned Aircraft Systems (UAS) sectors.

By leveraging Windform composites—carbon or glass fiber-reinforced thermoplastic materials specifically designed for 3D printing by CRP USA's partner, CRP Technology—alongside the SLS process, CRP USA is setting a new standard in product development. These advanced technologies enable the creation of functional, lightweight, and durable parts that can withstand the extreme conditions faced by industries like aerospace and autonomy.

Windform materials have passed the rigorous outgassing tests required by major international space agencies, making them a trusted solution for the most demanding aerospace applications. Additionally, CRP USA holds the AS9100D Certification, ensuring that its processes meet the highest quality standards in the aerospace and defense sectors.

The Role of Additive Manufacturing in Advancing Autonomy
Additive Manufacturing, especially the SLS process, allows for the production of complex, highly optimized components that are often too costly or unfeasible to produce with traditional methods. Using Windform composites, CRP USA can create parts with intricate geometries, embedded features, and superior mechanical and thermal properties.
These capabilities are critical in industries like aerospace and autonomy, where precision, reliability, and strength are paramount. The combination of SLS and Windform composites results in parts that are not only lightweight but also capable of enduring extreme environments, including high heat, pressure, and vacuum conditions, all without compromising performance.

Applications in Aerospace and Autonomy
CRP USA's expertise is especially impactful in the fields of aerospace and autonomous systems. Windform composites are ideal for the production of CubeSat and SmallSat structures, which must endure harsh space environments. These materials are designed to resist thermal degradation and maintain high performance under extreme temperatures and in vacuum conditions—making them a trusted solution for aerospace engineers.
In autonomous systems, CRP USA produces complex parts such as structural components, flaps with integrated reflective stoppers, and thermal device bodies. These parts take full advantage of the flexibility offered by additive manufacturing, allowing for the integration of multiple features into a single part—ultimately saving time and reducing costs.

Design Flexibility and Functional Integration
A significant advantage of Windform composites is their ability to support functional integration. Features like threaded holes, hinges, cable routing, and internal channels can be directly printed into components during the 3D printing process, eliminating the need for post-production assembly and reducing the risk of defects, which are common in traditional manufacturing.
Vu Mai, Senior Director of Sales at CRP USA, explains: "The strength-to-weight ratio of Windform composites allows us to produce ultra-light parts without sacrificing performance. The ability to print complex features directly into components accelerates production timelines and enhances overall efficiency."

Thermal Stability and Dimensional Precision
Windform composites also stand out for their thermal stability and dimensional precision, even in the most extreme conditions. These properties are essential in both aerospace and autonomous systems, where parts must maintain their structural integrity and function under high stress and temperature fluctuations.
Chris Brewster, CEO of CRP USA, adds: "Windform composites are engineered to endure both thermal stress and vacuum exposure, making them ideal for high-performance environments. They also eliminate the need for bearings and coatings, streamlining production and reducing component weight."

Shaping the Future of Autonomous Systems
At Xponential AUVSI 2025, CRP USA will provide attendees with a unique opportunity to see firsthand how additive manufacturing and Windform composites are shaping the future of autonomous systems. The company will showcase its capabilities in producing high-performance, complex parts that significantly accelerate the design-to-hardware cycle.
By leveraging Windform composites, CRP USA continues to lead the charge in additive manufacturing, helping engineers design and produce components that drive innovation across the aerospace, autonomy, and UAS industries.
CRP USA's approach to 3D printing offers companies unmatched speed, precision, and flexibility, allowing for the development of solutions that were once considered impossible with traditional manufacturing techniques.