Xenia’s (Vicenza, Italy) high-performance, fiber-reinforced pellets for large- scale additive manufacturing (LSAM) have supported the creation of a lamination mold by aerospace company Bercella Srl (Parma, Italy) for the 3.2-meter wings of Fly Mi’s (Milano, Italy) O.L.I.V.I.A (Optimised Lightweight Intelligent Vehicle for Immediate Assistance) UAV drone.

Source  | Xenia, Bercella and Fly Mi – EuroAvia Milano
Fly Mi is a student association at the Politecnico di Milano dedicated to designing, building and testing novel aircraft models — but particularly fixed-wing drones — fostering collaborations between the academic and professional world of aerospace. The O.L.I.V.I.A project, designed for the delivery of humanitarian aid in emergencies, was developed 2024-2025 and participated in UAS Challenge 2025, where it was awarded third place out of 42 participants and recognized under the competition’s Safety Award.

The UAV’s final design involved a fuselage comprising carbon fiber and Nomex honeycomb sandwich panels, as well as a carbon fiber wings manufactured using a closed mold process and cured in an autoclave. The wing’s molds were supported through Xenia Material’s Xecarb 40-C20-3DP polycarbonate reinforced with 20% carbon fiber, specifically designed for additive manufacturing. Bercella, in turn, used its large-scale 3D printing system and a milling process to transform these materials into the molds that made O.L.I.V.A a reality.

With a service temperature of 140°C, Xenia’s 3D printing filaments demonstrate optimal thermal resistance and high mechanical performance. Moreover, being a thermoplastic material, each mold is able to be shredded after use and recovered into their original granules for 100% recyclability.

Read about similar work Xenia has done collaboratively with Fly Mi for its Nyx drone.