How Markforged Parts Help Tsalla Aerospace Pvt. Ltd. Build Stronger and Smarter UAVs

The Challenge

For Tsalla Aerospace Pvt. Ltd., developing advanced unmanned aerial vehicles isn't just about great design—it's about speed, accuracy, and reliability. The company is known for its cutting-edge VTOL systems, designed for defense and commercial use. But during the development of one of their core UAV projects, they hit a roadblock.

They needed to build a tail assembly part for a wind tunnel test model. This component was crucial to verify whether their simulations and analytical models would actually hold up under real test conditions. The problem? Traditional manufacturing methods were too slow, expensive, and not precise enough. Making complex parts involved multiple joints and fasteners, which created small imperfections and affected aerodynamic performance.

They wanted a faster and more cost-effective way to make these parts as single, seamless components—without compromising on strength or precision.

The Solution

That's when they decided to bring in Markforged. Using the Markforged Mark Two printer and Onyx material, Tsalla produced the entire tail assembly as one solid piece. They also reinforced critical sections with continuous carbon fiber, which gave the part impressive strength and stiffness—perfect for real-world testing.

This change made a huge difference. Instead of waiting two weeks, they could now produce parts in just two days. The dropped sharply, and the surface finish and dimensional accuracy were exactly what they needed for proper wind tunnel testing.

What changed for Tsalla:

• Faster turnaround: Lead time went from 2 weeks to 2 days.
• Big cost savings: Prototyping costs came down by almost 80%.
• Precise testing: The printed parts matched the required tolerances.
• Stronger design: A single-part structure meant no joints, no weak points.

“We're really impressed with Markforged's technology and the impact it's had on our workflow,” said Vinayak, Founder and CEO of Tsalla Aerospace. “The dimensional accuracy is spot on, and the strength of the reinforced material is so good that we've moved from just prototyping to actually using these parts in production.”

The Impact

With this shift, Tsalla completely changed how they build and test UAV components. What started as a way to speed up prototyping quickly became a full production solution.

• Faster design validation: Test models now match real-world performance closely.
• More reliable UAVs: Strong, accurate printed parts make for better, longer-lasting aircraft.
• Quicker innovation: Rapid turnaround lets the team explore more design options.
• Streamlined production: The same printers used for prototypes are now used to make final components.

A Better Way to Build

By integrating Markforged's 3D printing technology into their process, Tsalla Aerospace has made their production faster, more flexible, and more cost-effective. They no longer have to rely on slow, expensive machining or compromise on design complexity.

This collaboration gives Tsalla the freedom to keep improving their UAVs, shorten development cycles, and bring stronger, more efficient aerial systems to life. In short, Markforged helps them build smarter—and move faster.