Tyto Robotics looks at 3D printed UAV rotors, and asks whether the noise and aerodynamic performance can be similar to that of commercially available plastic rotors?
In a project funded by the Nederlands Lucht- en Ruimtevaartcentrum Living Lab and utilizing Tyto Robotics’ Series 1585 thrust stand, researchers examined the potential of 3D-printed UAV rotors. They compared the aerodynamic and acoustic performance of 3D-printed and commercial propellers to assess the technology’s viability.
The Series 1585 thrust stand was used to characterize rotor performance, including thrust, torque, RPM, power, and efficiency.
The reference plastic propeller was 3D scanned and printed with PLA material and an FDM 3D printer. The research team also made some attempts with fiber reinforced printing, but the lines were thicker and resulted in a poor quality trailing edge, affecting performance and noise.
3D printed rotor on a Tyto Robotics thrust stand in a wind tunnel.
Before smoothing the surface of the 3D printed propeller, a simple performance test was performed (no acoustics were measured). The surface roughness had a notable effect on the thrust, which was in line with expectations for the low-Reynolds number blades.
After smoothing the rotor’s surface, both the original and 3D-printed rotor were tested in the anechoic room at NLR’s Aeroacoustic Wind Tunnel.
A comparison of the results shows that both rotors have a similar aerodynamic and aero-acoustic performance. This suggests that 3D printed propellers can be useful in the validation and experimentation of complex rotor blade designs aimed at reducing noise in small UAVs.
Find out more here, or visit the Tyto Robotics website for more information.
