CRP Technology understands that as the demand for more sophisticated and reliable unmanned aerial systems (UAS) grows, industry leaders are turning to advanced materials and manufacturing processes to meet these challenges.
A prime example of this is the collaboration between CRP Technology and Parrot in the creation of the Bebop 2 drone. This case study delves into how their partnership has leveraged the power of additive manufacturing, specifically Powder Bed Fusion (PBF) and the high-performance Windform® GT composite material, to produce a robust, flight-ready prototype that set new standards in the consumer drone market.
A Leap Forward in Drone Construction
In 2015, Parrot, a pioneer in the civil drone industry, introduced the Bebop 2 — a lightweight, compact drone renowned for its stability, maneuverability, and user-friendly controls. Central to its development was the integration of advanced materials and manufacturing techniques, which were crucial in achieving the drone’s high performance and reliability.
The collaboration with CRP Technology marked a significant advancement in the construction of drone components. By utilizing Windform GT, a glass fiber-filled composite material, and professional 3D printing through PBF technology, Parrot was able to create a functional prototype for the Bebop 2 that was not only strong and flexible but also optimized for rapid iteration and testing.
Drone Design & Additive Manufacturing
Traditionally, drone structures have been constructed using injection-molded parts made from glass-reinforced polyamide composites. However, this method often involves long lead times and high costs associated with the development of injection tooling.
To overcome these challenges, Parrot transitioned to the Powder Bed Fusion process, specifically Selective Laser Sintering (SLS), in collaboration with CRP Technology.
This shift allowed for significant improvements in several key areas:
- Optimized Structural Performance: The Bebop 2’s main structure and arms were produced using Windform GT, ensuring the drone was both lightweight and durable.
- Accelerated Iteration Cycles: Additive manufacturing enabled Parrot to rapidly produce and test multiple iterations of the drone’s design, significantly reducing development time.
- Enhanced Manufacturing Efficiency: The ability to produce small batches with consistent mechanical properties meant that Parrot could quickly respond to design changes and functional testing needs.
The use of Windform GT was particularly noteworthy. Parrot’s engineers conducted extensive testing to ensure that the natural frequencies of the parts made with this material were comparable to those produced by traditional injection molding techniques.
This validation was crucial for maintaining the drone’s stability and minimizing vibrations that could affect video quality during flight.
Overcomind Performance & Design Challenges
One of the major goals in the development of the Bebop 2 was to enhance the quality of the video captured during flight — a challenge often complicated by drone vibrations. Parrot approached this by focusing on smart design choices that reduced weight while maintaining structural integrity.
The successful use of Windform GT in achieving these objectives demonstrated the material’s superior performance, particularly in terms of durability and resistance to the rigorous testing conducted by Parrot’s team.
For a consumer drone like the Bebop 2, which is likely to experience frequent falls, especially with beginner users, the toughness of the Windform® GT material was essential. It was the only SLS material that withstood the stringent testing protocols, ensuring that the drone’s structure could endure the demands of real-world use.
Advantages of Additive Manufacturing
The partnership between Parrot and CRP Technology highlighted several advantages of using additive manufacturing and Windform GT in drone development:
- Flexibility in Production: The ability to produce small batches with reliable mechanical properties enabled Parrot to deliver functional prototypes and support the development of other product functionalities, such as flight performance.
- Aesthetic and Functional Excellence: The material offered not only the necessary strength but also a pleasing aesthetic quality, which is important in consumer products.
- Efficiency in Manufacturing: The use of PBF technology eliminated the need for support structures and complex post-processing. CRP Technology’s expertise in traditional finishing ensured that the parts were smooth and polished where required, further enhancing the product’s quality.
CRP Technology’s contribution extended beyond just manufacturing; their fast response times, collaborative approach, and ability to deliver high-quality outputs were instrumental in the successful development of the Bebop 2. The body structure of the drone was processed in under 24 hours from the receipt of the CAD file, underscoring the efficiency and speed of this advanced manufacturing approach.
The collaboration between CRP Technology and Parrot in the development of the Bebop 2 drone is a testament to the transformative power of additive manufacturing and advanced composite materials like Windform GT. By embracing these technologies, Parrot was able to push the boundaries of drone design and production, delivering a product that set new benchmarks in the consumer drone market.
As unmanned systems continue to evolve, the integration of innovative materials and manufacturing techniques will be key to meeting the ever-growing demands of the industry.
Read the original case study, or find out more on the CRP Technology website.
