Home Press Releases & Guest Posts The Construction of an Unmanned Aerial System Using AM and Windform Materials

The Construction of an Unmanned Aerial System Using AM and Windform Materials

The project has involved two companies: FLYING-CAM and CRP Technology. The aim is the construction of a Special Aerial Response Automatic Helicopter: SARAH

FLYING-CAM ignited the close range aerial filming concept in the 1970s and has been leading the way with its Award-winning Flying-Cam II in the motion picture industry. Today FLYING-CAM continues to guide the innovation with the state-of-the art Flying-Cam 3.0 SARAH.

The Flying-Cam 3.0 SARAH is an electric VTOL (Vertical Take Off and Landing) UAS (Unmanned Aerial System) featuring 25 Kg TOW and 30 minutes flight time with a 5 Kg payload. SARAH stands for Special Aerial Response Automatic Helicopter. Incorporating efficient aerodynamics, innovative flight modes and modular interchangeable payloads all in a portable unit that is quickly deployable, the SARAH system provides unprecedented centimetre precision level aerial 3-D imagery intelligence.

SARAH has reached production stage. The Spanish Aerospace Research Centre FADA-CATEC has taken delivery of its first SARAH systems. They are used for air traffic management and general aviation research, technology & development projects in partnership with BOEING, EADS and AIRBUS MILITARY. Two weeks training was sufficient for the Client to take control of the whole system.

FLYING-CAM dedication is to design field proven state-of-the-art products. Each SARAH System is the result of smart and deep thinking, with the KISS & JEEP concepts as a goal: Keep It Simple Stupid and Just Enough Essential Parts.

As a Light UAS, 25 Kg TOW including payload, SARAH is recognized to be the most advanced technology available today: easy to use, maintenance free propulsion, innovative FLYING-CAM proprietary Automatic Pilot System and most importantly the best real time image quality, Day or Night, the core competence of the FLYING-CAM Company.


SARAH supersedes heavier and more costly systems. Moreover, the 25 Kg category regulation is less demanding than for heavier platform which further reduces the operating costs.

Its applications include Emergency Management, Surveillance, Defence, ENG & EFP Broadcast TV and Motion Picture Production.

The collaboration with CRP Technology 

The first Flying-Cam Airframe Structure was made with composite moulded material.

FLYING-CAM moved to SLS technology in collaboration with CRP Technology in order to accelerate iteration generation, improve manufacturing time and facilitate production in series. Alongside it allows easier customization of the platform.

Main Flying-Cam parts using Additive Manufacturing and the Windform materials:

  • Airframe structure
  • Air guide cooling system
  • Tail unit
  • Main battery connection

The requirements were fast iteration process, best ratio between structural strength and weight, acceptable consistent result and opportunity to combine multiples functionalities from one unique part.


CRP Technology provided fast response time to new requirements, very good cooperation with our Engineer and CAD designer and best output quality with unique proprietary process.



LS Composite materials for 3D printing and additive manufacturing.

Windform composite SLS materials were born from the study-research of R&D department of CRP Technology and international market needs.

The CRP Technology’s Additive Manufacturing department gathers market requests for more then 10 years and passes them to the R&D department. Who in turn develops new materials and services, through continuous innovation, to achieve always the maximum satisfaction of the service bureau, and gives the highest value for its final customers.

Windform is the ideal composite SLS material that is able to satisfy the needs of international market of Additive Manufacturing. The SLS materials Windform can guarantee: originality, innovation, reliability, and mechanical performances; a structured customer care service to gather the needs and inquiries of customers together with the R&D department of CRP Technology, leader in the field of Additive Manufacturing. The Windform SLS composite materials guarantee: – High prototype performance and definition level for the maximum adherence to the conception of the project.


FLYING-CAM is pioneer in the development and application of rotary wing Light Unmanned Aerial System for the most demanding Motion Picture Industry. Winner of an Academy Award for Technical Achievement from the Academy of Motion Pictures Arts and Science, FLYING-CAM has established their reputation as the undisputed  reference in state-of-the-art Close Range Aerial Filming technology. Clients includes: Harry Potter, James Bond, Mission Impossible, Red Cliff and many others.

Since 7 years FLYING-CAM has focused on the development of the next generation Rotary Wing light UAV. Their Aerial Robotic Engineering team is now strategically focused on precision 3D aerial Imagery Intelligence (IMINT) for multiple markets: Law Enforcement, Defence, Civil Security, News & Entertainment and the related Services markets.

FLYING-CAM is based in Belgium, USA and Hong Kong.

About CRP Technology

CRP Technology is based in Modena, Northen Italy, in the area of the so-called Italian MotorValley. This district is one of the most important in the luxury car  sector and motorsport, in fact, it hosts the most important cars constructors.
The activity of CRP Technology is dedicated to additive manufacturing, ranging from the motorsport industry to the aviation, aerospace industry and UAV. CRP Technology also produces and sells worldwide composite materials for additive manufacturing, called Windform. The family of the Windform is composed of: Windform XT 2.0, Windform LX 2.0, Windform GF, Windform FX and Windform PS. Each material is characterised by mechanical features that make them the suitable materials for several applications.

CRP Technology has long expertise in the technique of Selective Laser Sintering in high-performing sectors. They worked together with the most important racing teams at worldwide level, in particular in the building of parts and components that were tested in wind tunnel, but also used on track for the race.

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