3D Printed Drone Fuselage
The design of cutting-edge UAVs demands constant iteration and experimentation. 3D printing allows for rapid physical prototypes, accelerating the cycle of testing, analysis, and refinement.
Client:
Ultra
Service Category:
3D Modeling
Product Stage:
Concept
Example Product:
Fixed-Wing UAV
The Project
Rapid Prototyping for Advanced Aircraft Design
Partnering with the University of Southampton and Ultra Electronics to develop a 3D printed fuselage for a concept folding UAV, optimizing its design through structural analysis and iterative prototyping.
3D Modeling
Precise models incorporating complex surfacing, topology optimization, and constraints for both packaging and aerodynamics.
General Assembly
Creation of assembly models to simulate folding mechanisms, conduct motion analysis, and calculate center of gravity.
Design for Manufacture
Ensuring model printability, including features for support removal and optimizing for nylon materials.
Rapid Prototyping
Multiple iterative prints of fuselage and wing components to enable design refinements and physical testing.
The Challenge
Overcoming Design Constraints in a Tight Timeline
- Translating design requirements into an aerodynamic, 3D fuselage model that maximizes internal volume while fitting within housing dimensions.
- Rapidly producing physical prototypes to facilitate testing and design adjustments in a fast-paced development environment.
The Result
Accelerated Design Iteration
Rapid prototyping allowed for numerous design concepts to be tested and improved upon, streamlining the development process.
FEA-Driven Optimization
Finite Element Analysis of the models informed targeted strengthening and design tweaks for improved performance.
FEA-Driven Optimization
Finite Element Analysis of the models informed targeted strengthening and design tweaks for improved performance.
Realistic Prototypes
Nylon prints with post-processing provided tangible models for aerodynamic testing, component integration, and weight analysis.
Downstream Applications
Future-Proofing the Design: Flexibility for Refinement
- Presentation Impact: Exploded view renders clearly illustrate assembly and component relationships, while in-situ renders showcase the UAV in realistic operational environments. These visuals elevate presentations and project proposals.
- Iteration & Refinement: The 3D CAD assets remain a valuable resource for future design changes. Modifications can be made quickly for new iterations, supporting further testing, and optimizing the aircraft concept.