At Skaza, we successfully developed a new material as part of a recent R&D project for a client. The material significantly improves the mechanical performance of plastic components used in the injection moulding process for high-performance drones.
The core challenge was achieving the right balance between stiffness and toughness. While the client’s existing material provided sufficient stiffness—enabling the drone to operate effectively at full load and speeds of up to 130 km/h—it proved too brittle in practice. Unexpected mechanical stress (such as accidental drops or improper take-offs) often caused cracking due to low impact resistance. Damage most frequently occurred at the structurally most exposed part of the drone: the junction between the arm and the main body.
Close collaboration with the client was essential. It allowed us to test each material iteration under real-world conditions and ultimately develop a solution that is flexible enough to absorb impact, while maintaining the high performance required of the final product.
“What makes this especially important is that this was the first material developed entirely in-house. The ability to create our own material formulations tailored to specific applications is a strategic direction we are strongly pursuing, and it marks another key step toward full vertical integration of Skaza’s production processes,” explains Dr. Urban Feguš, Director of Strategic Development and Innovation at Skaza.
Comprehensive Support in Developing Innovative, Sustainable Solutions
This project represents a strategic milestone for Skaza. It laid the foundation for the development of in-house material formulations for injection moulding, which can be rapidly adapted to the specific needs of our partners. Internal material development is a key differentiator, enabling faster response to market demands and the co-creation of custom solutions with our industrial clients.
At Skaza, we offer end-to-end support in every phase of material development:
- Formulation development based on functional and mechanical requirements,
- Validation and testing under real-world conditions,
- Series production of new materials (up to 400 tons/year),
- Serial manufacturing of products from new materials using modern injection moulding lines,
- Technical support for product upgrades with improved functionality or reduced environmental impact.
The new material developed for the high-performance drone has proven, in practice, that Skaza can quickly design, test, and scale production of solutions that perform reliably under real conditions. Our in-house compounding line enables us to create materials that are precisely tailored to the technical demands of modern industry.
📩 If you’re looking for a development partner to create materials tailored to your application, get in touch: www.skaza.com/contact
Skaza – Material development that delivers results.