Report On AM For UAV Manufacturing: $2.3 Billion In Value By 2027

In this report, it is projected that the yearly value of AM manufactured parts in the UAV industry to reach $1.9 billion, driving over $400 million in yearly sales of AM equipment, software, materials and services. Further details of this report including a detailed description, table of contents and downloadable excerpt can be found at: https://smarttechmarke.wpengine.com/product/additive-manufacturing-for-the-droneuav-industry-an-opportunity-analysis-and-ten-year-forecast/. 

Integration of Topological and Functional Optimization in Design for Additive Manufacturing

Additive Manufacturing (AM) technologies has brought unprecedented freedom to the fabrication of functional parts with high complex, multi-material and gradient density structure.

However, currently only traditional design methods are available for AM design process, which do not take full advantage of AM capabilities. Therefore, a new design method with the consideration of all aspects of AM advantages is urgently in need.

A detailed literature review on traditional design methods is presented with focused attention on the potential of using these methods to design functional parts for additive manufacturing processes. Based on thorough understanding and comparison of current structure design methods, a new design approach that integrates topological and functional optimizations for AM products is presented.

With this method, an essential link is established between topological optimization result and various functional parameters of complex structure. Parts can be designed in multi levels for multi functions simultaneously. This design method provides an important foundation for future research on designing AM products with improved multiple functions and optimized topology.

Read more: http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1919996

Stratasys Lesson Guide: Drone Quadcopter

Design, 3D print and assemble a working drone quadcopter.

Read more:

http://usglobalimages.stratasys.com/Main/Files/Learning%20Modules/LG_Drone_0417a_Web.pdf?v=636287955814207375

Optisys reduce UAV antenna parts by 99% with AM and ANSYS

Aerospace is frequent early adopter of Additive Manufacturing as the technology promises dramatic weight reductions.

Antennas are an ever-present component in all commercial and military aircraft, as well as in satellites, UAVs and ground terminals.

However, Optisys believes they are typically too heavy, particularly with the RF antennas implemented in aerospace.

Following a partnership with U.S software company ANSYS, Optisys developed an alternative method to 3D print the components by utilizing simulation software.

With the two technologies, Optisys is able to design parts that are significantly lighter with savings of up to 95%. By doing so, Optisys states it has managed to reduce not only the number of parts, but also the weight of parts, the lead times and the production costs.

Optisys has several pending patents and is hoping to work with more aerospace companies and academics to advance the use of Additive Manufacturing in this field. 

Rotational 3D printing of damage-tolerant composites

Natural composites exhibit exceptional mechanical performance that often arises from complex fiber arrangements within continuous matrices.

Inspired by these natural systems, a team of engineers from prestigious universities have developed a Rotational 3D Printing method that enables spatially controlled orientation of short fibers in polymer matrices solely by varying the nozzle rotation speed relative to the printing speed.

Using this method, they have fabricated carbon fiber–epoxy composites composed of volumetric pixels (voxels) with programmably defined fiber arrangements, including adjacent regions with orthogonally and helically oriented fibers that lead to nonuniform strain and failure as well as those with purely helical fiber orientations akin to natural composites that exhibit enhanced damage tolerance.

Their approach broadens the design, microstructural complexity, and performance space for fiber-reinforced composites through site-specific optimization of their fiber orientation, strain, failure, and damage tolerance.

More info:

http://www.pnas.org/content/pnas/115/6/1198.full.pdf

Boeing Enlists Oerlikon for 3-D-Printed Plane Parts

According to Leo Christodoulou, CTO at Boeing, the two companies will "work together to standardize additive manufacturing operations" in the pursuit of an efficient and reliable process. Boeing says it has around 50,000 parts flying today that were created via 3-D printing. Through a five-year pact with Oerlikon, it hopes to get to the point that it can have a large-scale supply chain for 3-D-printed aerospace parts that meet quality and cost targets.

Additive manufacturing in UAVs: Challenges and potential

UAVs are gaining popularity due to their application in military, private and public sector, especially being attractive for fields where human operator is not required.

Light-weight UAVs are more desirable as they have better performance in terms of shorter take-off range and longer flight endurance. However, light weight structures with complex inner features are hard to fabricate using conventional manufacturing methods.

The ability to print complex inner structures directly without the need of a mould gives Additive Manufacturing (AM) an edge over conventional manufacturing. Recent development in composite and multi-material printing opens up new possibilities of printing lightweight structures and novel platforms like flapping wings with ease.

This paper explores the impact of Additive Fabrication on aerodynamics, structures and materials used for UAVs. The review will discuss state-of-the-art

AM technologies for UAVs through innovations in materials and structures and their advantages and limitations. The role of Additive Fabrication Technology to improve the performance of UAVs through smart material actuators and multi-functional structures will also be discussed.

More info:

https://www.researchgate.net/profile/Shweta_Agarwala/publication/311978361_Additive_manufacturing_in_unmanned_aerial_vehicles_UAVs_Challenges_and_potential/links/59dad4e6aca272e6096bf240/Additive-manufacturing-in-unmanned-aerial-vehicles-UAVs-Challenges-and-potential.pdf