CRP Technology has released a case study illustrating the manufacture of an unmanned aerial system (UAS) using Powder Bed Fusion process with composite polymers fibres-reinforced (Laser Sintering technology) and Windform composite materials.
The project involved two companies: CRP Technology and Hexadrone. The aim was to construct Hexadrone’s first fully modular and easy-to-use drone for industrial and multi-purpose tasks, made for extreme weather conditions thanks to rugged, waterproof design.
The collaboration between CRP Technology and Hexadrone
Hexadrone requested CRP to devise the functional prototype of the Tundra-M, Hexadrone’s very first mass-produced drone.
Hexadrone looked to SLS technology in collaboration with CRP Technology in order to accelerate iteration generation, improve manufacturing time and facilitate series production.
Additive manufacturing technology is often faster than designing and producing a tool for traditional manufacturing technologies. Furthermore, 3D printing has given engineers more flexibility in the timeline to make design improvements and being able to think outside of limitations caused by traditional tooling. This choice made it possible to substantially reduce the costs and has been very convenient in terms of timing when compared to traditional production methods. The unique properties of AM Windform® XT 2.0 and Windform® SP composite materials have allowed system optimization that successfully withstands the design requirements due to space limitations and the extreme conditions during flights.
The requirements were fast iteration process, best ratio between structural strength and weight, acceptable consistent result and opportunity to combine multiple functionalities from one unique part. CRP Technology provided fast response time to new requirements, very good cooperation with Hexadrone and CAD designer and best output quality with unique proprietary process.
Hexadrone CEO, Alexandre Labesse, commented; “We have engineered our drone by means of a cautious, multifaceted, and collaborative based approach with the involvement of broad-based stakeholders. In the course of two years of consulting, research and development we have gathered all the advice and customers’ testimonials useful to its design and which finally helped us in the process of devising an ideal UAV solution.”
Evaluation criteria/critical problems overcome through SLS technology and Windform materials
Main stress/efforts involved in the application were:
- Compressive stress
- Tensile stress
- Vibrations
- Traction stress
The critical problem of this application resides in a lack of precision resulting in a scale gain. This gain lies between 0.15 and 0.20 millimeters. If not anticipated, this gain can compromise the assembling of the different parts as trying to fit them together.
Tundra-M drone: Parts in Windform composite materials
The most interesting parts that have been made using the Windform® SP and the Windform® XT 2.0.
Body Frame
The body frame is composed of the main frame plus a removable top lid. This component contains the brain of the Tundra-M (the main circuit boards as well as the cooling system).
CEO Hexadrone Alexandre Labesse said; “To devise this component, we were in need of a water-resistant, durable and sturdy material. Moreover, this sturdy frame comes with an emergency parachute, four removable and scalable arms, two batteries as well as three easily interfaceable accessories.”
The Windform® composite material used for the body frame is Windform® SP due to its mechanical and thermal properties.
The Arms
The arms are composed of motor supports plus the removable arms plus its interlock base which allows the user to easily tighten the four arms with the support of a patented “tension ring”: This stiff system allows the user to connect and disconnect the interchangeable arms on a discretionary basis.
CEO Hexadrone Alexandre Labesse, commented; “Our patented technology offers a reliable and sturdy connection while being a waterproof solution in case of inclemency. This interlocking connection is also able to handle the stress due to leverage forces. Those leverage forces are primarily generated through the components at the end applying a constant force through masses.”
The Windform® composite material used for the arms is Windform® XT 2.0.
Read the full case study here, or visit the CRP Technology website to find out more.
