3D printed UAV begins trials at Sheffield
A team of engineers from the Advanced Manufacturing Research Centre (AMRC) at the University of Sheffield has designed, manufactured and flight-tested a prototype Unmanned Aerial Vehicle (UAV) constructed entirely of ABS plastic, using Fused Deposition Modelling (FDM) technology.
The researchers believe the aircraft, which was printed using a Stratasys Fortus 900mc FDM machine, could one day form the basis of cheap, disposable UAVs that can be built and deployed within as little as 24 hours.
The UAV has already completed a flight test as a glider. The engineers are now developing an electric ducted fan propulsion system that will be incorporated into the airframe's central spine.
They also plan to develop the craft for guidance by GPS or camera technology, controlled by an operator wearing first person-view goggles.
Design engineer Dr Garth Nicholson, who led the project, said: "Following successful flight testing, we are working to incorporate blended winglets and twin ducted fan propulsion. We are also investigating full on-board data logging of flight parameters, autonomous operation by GPS, and control by surface morphing technology. Concepts for novel ducted fan designs are also being investigated".
The UAV weighs less than 2kg and comprises nine parts that can be snapped together.
Development engineer Mark Cocking commented: "All parts required for the airframe can be combined onto a single build within the DPGs Fortus 900 machine, taking less than 24 hours with ABS-M30 material. Before design for additive manufacture optimisation, this airframe would take over 120 hours to produce."
According to Cocking, all the components were developed specifically for additive manufacture. The engineers are now evaluating the potential of nylon as a printing material, which they say would make the UAV 60% stronger with no increase in weight.
