Additive Manufactured Air-Cooled Wankel Rotary Engine

Advanced Innovative Engineering (AIE) has unveiled the 40ACS, an air-cooled Wankel rotary engine designed using additive manufacturing techniques, delivering 5BHP (3.7kW) and weighing just 2kg (4.4lbs) By Joe Macey / 04 Dec 2024

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An air-cooled Wankel rotary engine that delivers 5 BHP (3.7 kW) of power has been launched.

Wankel rotary engine from Advanced Innovative Engineering (AIE)
Wankel rotary engine from Advanced Innovative Engineering.

The 40ACS from Advanced Innovative Engineering (AIE), designed with cutting-edge Additive Manufacturing techniques, is compact and lightweight, and is said to set a new benchmark for UAV propulsion systems, robotics, and other advanced applications.

The integration of additive manufacturing in the production of 40ACS’s major components allows AIE to achieve exceptional precision, reduce material waste, and enhance durability. This advanced manufacturing method underscores AIE’s commitment to innovation, ensuring the engine’s components meet the highest performance and reliability standards while enabling a streamlined, lightweight design.

The core of the engine weighing just 2kg (4.4lbs) and offering an unparalleled power-to-weight ratio. The 40ACS is an ideal propulsion solution for UAVs and other compact systems requiring high efficiency and reliability. The engine is equipped with AIE’s proven and patented SPARCS (Self-Pressurizing-Air Rotor Cooling System) technology, which delivers superior thermal management for efficient, clean, and dependable operation. It supports multiple fuel types, including gasoline, AVGAS, Jet A-1, JP5 and JP8, providing versatility for diverse mission requirements.

With applications spanning defence, surveillance, agriculture, disaster relief, and scientific research, the 40ACS is designed to excel in performance-critical environments. The engine’s minimal moving parts and simplified architecture—enabled by Additive Manufacturing—ensure reduced maintenance needs, long-term reliability, and seamless integration into various systems.

By combining Additive Manufacturing with patented SPARCS technology, AIE has created a propulsion system that meets the growing demands of modern aerospace and robotics. The 40ACS represents the future of compact, efficient, and sustainable engines, offering unmatched versatility for mission-critical applications.

Posted by Joe Macey Joseph Macey is a Content Specialist at Unmanned Systems Technology. Since joining in 2022, he has focused on emerging technologies in unmanned systems, with particular expertise in Counter-UAS, communication systems, and camera technologies. A graduate of Falmouth University in Journalism, Joseph began his career in 2019 as a local reporter. His journalism experience not only sharpens his reporting but also enhances his ability to conduct in-depth interviews, enabling him to deliver authoritative insights on the latest industry trends. Connect
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